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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Fatigue behavior of two alloys for Space Shuttle applications

Two superalloys used extensively in the Space Shuttle main engine are Incoloy 903 and Inconel 718. The fatigue behavior of the two alloys under varying conditions is considered. Three heats of Incoloy 903 and two of Inconel 718 were used in the study. Material was tested in several conditions, including mill polish, longitudinal mill polish, transverse mill polish, chemically milled, chemically milled plus shotpeened on one side and on both sides, gas tungsten arc welded, and electron beam welded. Both round and flat tensile specimens were tested in universal test machines. It was found that surface condition influences test results. Transverse scratches resulting from polishing and rougher surfaces lower the stress at runout in relation to that obtained on longitudinally polished and/or smooth-surfaced specimens.

Adsit, N. R.↗
NASA NTRS1989

Manufacturing implementation of off-line programming for the Space Shuttle Main Engines

An account is given of the efforts made to implement an off-line programming (OLP) system for a gas tungsten arc welding robot in actual manufacturing operations, namely those involved in the manufacture of the SSMEs. In conjunction with a real-time sensor control system, the OLP constitutes the Advanced Robotic Welding System, or 'AROWS'. OLP's task is to develop a robot-motion path without the initial use of the robot to 'teach' the characteristics of such motion; actual process parameters are recorded by OLP and correlated with the position along the weld.

Sliwinski, K. E.↗
NASA NTRS2009

NASA Tech Briefs, June 2009

Topics covered include: Device for Measuring Low Flow Speed in a Duct, Measuring Thermal Conductivity of a Small Insulation Sample, Alignment Jig for the Precise Measurement of THz Radiation, Autoignition Chamber for Remote Testing of Pyrotechnic Devices, Microwave Power Combiners for Signals of Arbitrary Amplitude, Synthetic Foveal Imaging Technology, Airborne Antenna System for Minimum-Cycle-Slip GPS Reception, Improved Starting Materials for Back-Illuminated Imagers, Multi-Modulator for Bandwidth-Efficient Communication, Some Improvements in Utilization of Flash Memory Devices, GPS/MEMS IMU/Microprocessor Board for Navigation, T/R Multi-Chip MMIC Modules for 150 GHz, Pneumatic Haptic Interfaces, Device Acquires and Retains Rock or Ice Samples, Cryogenic Feedthrough Test Rig, Improved Assembly for Gas Shielding During Welding or Brazing, Two-Step Plasma Process for Cleaning Indium Bonding Bumps, Tool for Crimping Flexible Circuit Leads, Yb14MnSb11 as a High-Efficiency Thermoelectric Material, Polyimide-Foam/Aerogel Composites for Thermal Insulation, Converting CSV Files to RKSML Files, Service Management Database for DSN Equipment, Chemochromic Hydrogen Leak Detectors, Compatibility of Segments of Thermoelectric Generators, Complementary Barrier Infrared Detector, JPL Greenland Moulin Exploration Probe, Ultra-Lightweight Self-Deployable Nanocomposite Structure for Habitat Applications, and Room-Temperature Ionic Liquids for Electrochemical Capacitors.

Source record↗
NASA NTRS1969

Mixing weld gases offers advantages

Argon added to helium during gas tungsten arc cover-pass welding in the horizontal position results in a better controlled wider bead width, increased arc stability, and reduction in heat input. Adequate filler material wetness and penetration pass coverage is possible with only one pass.

May, J. L.↗
NASA NTRS1995

Parameters For Welding Aluminum/Lithium Alloys

Report discusses parameters that must be controlled to properly weld aluminum/lithium alloys. Describes experiments conducted to determine gas-shielding parameters yielding acceptable welds.

Gallagher, Robert L.↗
DOE OSTI2026

SPC-70791 Rev 0 MARVEL Inert Gas Subsystem, Secondary Coolant Management Subsystem, and Secondary Coolant Cover Gas Subsystem Tubing and Valve Specification

This specification covers the requirements and details for the selection, testing, cleaning, marking, shipping, inspection and installation (including welding) of the Inert Gas Subsystem, Secondary Coolant Management Subsystem, and Secondary Cover Gas Management Subsystem from the Valve Panel up to the classification division, the patch panel of the upper confinement. Including NaK, argon, eutectic gallium indium tin (eGaInSn), and helium fill tubing, valves, and hangers. These systems consist of the necessary straight lengths, elbows, reducers, fittings, tube connections, instrument taps, and valves called for by applicable drawings. All components shall be procured as ASME Section III Class 2 unless otherwise modified hereinafter. Pressure relief valves have been sized to prevent overpressure in the event there is full regulator flow. This is documented in ECAR-7365.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
NASA NTRS1996

Role of the micro/macro structure of welds in crack nucleation and propagation in aerospace aluminum-lithium alloy

Al-Li alloys offer the benefits of increased strength, elastic modulus and lower densities as compared to conventional aluminum alloys. Martin Marietta Laboratories has developed an Al-Li alloy designated 2195 which is designated for use in the cryogenic tanks of the space shuttle. The Variable Polarity Plasma Arc (VPPA) welding process is currently being used to produce these welds [1]. VPPA welding utilizes high temperature ionized gas (plasma) to transfer heat to the workpiece. An inert gas, such as Helium, is used to shield the active welding zone to prevent contamination of the molten base metal with surrounding reactive atmospheric gases. [1] In the Space Shuttle application, two passes of the arc are used to complete a butt-type weld. The pressure of the plasma stream is increased during the first pass to force the arc entirely through the material, a practice commonly referred to as keyholing. Molten metal forms on either side of the arc and surface tension draws this liquid together as the arc passes. 2319 Al alloy filler material may also be fed into the weld zone during this pass. During the second pass, the plasma stream pressure is reduced such that only partial penetration of the base material is obtained. Al 2319 filler material is added during this pass to yield a uniform, fully filled welded joint. This additional pass also acts to alter the grain structure of the weld zone to yield a higher strength joint.

Talia, George E.↗
DOE OSTI2024

Titanium Wire Arc Additive Manufacturing Inert Enclosure and Material Handling Safety Considerations

Wire arc additive manufacturing (WAAM) via metal inert gas (MIG)/gas metal arc welding (GMAW) is a viable option for fabrication of large-scale titanium parts; however, it introduces new safety hazards associated with both the material and the additional system hardware required for the process. Localized gas shielding of the weld arc via standard GMAW torch is inadequate for titanium due to its affinity for oxygen; thereby requiring the use of an inert enclosure to protect the weld from entraining oxygen. The use of the inert enclosure presents potential safety hazards such as operator asphyxiation and brings up discussion of confined space considerations. In addition, the titanium welding process creates pyrophoric titanium soot residue around the deposit, which can undergo deflagration during part cleaning and part removal. This paper provides an overview of the titanium WAAM process along with safety considerations for the design and operation of the inert enclosure as well as functional solutions for the safe handling of the titanium soot by-product.

Walters, Alex↗
NASA NTRS1988

A Generalized Method for Automatic Downhand and Wirefeed Control of a Welding Robot and Positioner

A generalized method for controlling a six degree-of-freedom (DOF) robot and a two DOF positioner used for arc welding operations is described. The welding path is defined in the part reference frame, and robot/positioner joint angles of the equivalent eight DOF serial linkage are determined via an iterative solution. Three algorithms are presented: the first solution controls motion of the eight DOF mechanism such that proper torch motion is achieved while minimizing the sum-of-squares of joint displacements; the second algorithm adds two constraint equations to achieve torch control while maintaining part orientation so that welding occurs in the downhand position; and the third algorithm adds the ability to control the proper orientation of a wire feed mechanism used in gas tungsten arc (GTA) welding operations. A verification of these algorithms is given using ROBOSIM, a NASA developed computer graphic simulation software package design for robot systems development.

Fernandez, Ken↗
NASA NTRS1993

Method for defect free keyhole plasma arc welding

A plasma arc welding process for welding metal of increased thickness with one pass includes operating the plasma arc welding apparatus at a selected plasma gas flow rate, travel speed and arc current, to form a weld having a penetration ratio to weld height to weld width, and maintaining the penetration ratio at less than 0.74. Parameters for the plasma gas flow rate, travel speed and arc current are adjusted to a steady state condition during a start up period and maintained during the steady state condition to complete a weld. During a terminal stopping period, the travel speed is stopped and instantaneously replaced by filler wire which adds material to fill the keyhole that had been formed by the welding process. Parameters are subsequently adjusted during the stopping period to terminate the weld in a sound manner.

Harwig, Dennis D.↗
NASA NTRS1988

The potential of a GAS can with payload G-169

The feasibility of using welding for the construction, expansion and emergency repair of space based structures is discussed and the advantages of gas tungsten arc welding (GTAW) over other welding techniques are briefly examined. The objective and design concept for the G-169 Get Away Special payload are described. The G-169 experiment will allow the comparison of a space GTA welded joint with a terrestrial GTA welded joint with all parameters held constant except for gravitational forces. Specifically, a bead-on-plate weld around the perimeter of a 2 inch diameter stainless steel pipe section will be performed. The use of Learjet microgravity simulation for the G-169 and other Get Away Special experiments is also addressed.

Tamir, David↗
NASA NTRS1987

Optical Welding Torch

Gas/tungsten-arc welding torch supports electrode at center while enabling viewing of weld area along torch axis. Gas torch accommodates lens and optical fibers, all part of vision system for welding robot. Welding torch includes spoked structure in central bore of optical body. Structure supports welding electrode, carries electric current to it, and takes heat away from it. Spokes formed by drilling six holes 60 degrees apart around center line of torch.

Richardson, R. W.↗
NASA NTRS1999

ARC and Melting Efficiency of Plasma ARC Welds

A series of partial penetration Variable Polarity Plasma Arc welds were made at equal power but various combinations of current and voltage on 2219 Aluminum. Arc efficiency was measured calorimetrically and ranged between 48% and 66% for the conditions of the welds. Arc efficiency depends in different ways on voltage and current. The voltage effect dominates. Raising voltage while reducing current increases arc efficiency. Longer, higher voltage arcs are thought to transfer a greater portion of arc power to the workpiece through shield gas convection. Melting efficiency depends upon weld pool shape as well as arc efficiency. Increased current increases the melting efficiency as it increases the depth to width ratio of the weld pool. Increased plasma gas flow does the same thing. Higher currents are thought to raise arc pressure and depress liquid at the bottom of the weld pool. More arc power then transfers to the workpiece through increasing plasma gas convection. If the power is held constant, the reduced voltage lowers the arc efficiency, while the pool shape change increases the melting efficiency,

McClure, J. C.↗
NASA NTRS1993

Bulge formed cooling channels with a variable lead helix on a hollow body of revolution

A method of constructing a nozzle having cooling channels comprises a shell and a liner which are formed into a body of revolution having an axis of revolution. Helical welds are formed to hold the liner and shell to each other with a channel position being defined between each pair of helical welds. Pressurized fluid which may be a gas or a liquid, is introduced between the weld pairs to outwardly bulge the material of at least one of the liner and shell to define the channels.

McAninch, Michael D.↗
NASA NTRS1994

Improved Abutting Edges For Welding In Keyhole Mode

Welds of better quality made, and/or heat input reduced. Improved shapes devised for abutting edges of metal pieces to be joined by plasma arc welding in keyhole mode, in which gas jet maintains molten hole ("keyhole") completely through thickness of weld joint. Edges of metal pieces to be welded together machined to provide required combination gap and shaped, thin sections. Shapes and dimensions chosen to optimize weld in various respects; e.g., to enhance penetration of keyhole or reduce heat input to produce joint of given thickness.

Harwing, Dennis D.↗
NASA NTRS1984

Bending fatigue of electron-beam-welded foils. Application to a hydrodynamic air bearing in the Chrysler/DOE upgraded automotive gas tubine engine

A hydrodynamic air bearing with a compliment surface is used in the gas generator of an upgraded automotive gas turbine engine. In the prototype design, the compliant surface is a thin foil spot welded at one end to the bearing cartridge. During operation, the foil failed along the line of spot welds which acted as a series of stress concentrators. Because of its higher degree of geometric uniformity, electron beam welding of the foil was selected as an alternative to spot welding. Room temperature bending fatigue tests were conducted to determine the fatigue resistance of the electron beam welded foils. Equations were determined relating cycles to crack initiation and cycles to failure to nominal total strain range. A scaling procedure is presented for estimating the reduction in cyclic life when the foil is at its normal operating temperature of 260 C (500 F).

Saltsman, J. F.↗