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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Influence of Thermophysical Property Variability on Thermal Predictions of Ti-6Al-4V

The additive manufacturing (AM) industry has experienced rapid growth in recent decades as industrial interest in the process has grown. Because of this, there are many groups interested in simulations of the AM process. However, the influence of thermophysical property variability on the melt pool geometry during processing of various AM alloys is unclear. The goal of my work at NASA Langley Research Center (LaRC) was to characterize this influence on Ti-6Al-4V during AM processing alongside developing a tool to enable equivalent studies on other AM materials. To facilitate this process, a database tool was developed to contain and organize thermophysical data previously reported by primary sources. The specific thermophysical properties of interest for this study were density, specific heat capacity, and conductivity. Thermal diffusivity was calculated using the other three properties. This data was then fit with a Gaussian distribution and then randomly sampled from using Monte Carlo random value sampling. Using the Rosenthal equation, this sample data was used to simulate the temperature field during additive manufacturing and extract the melt pool geometry. Specifically, the melt pool’s length, width, and depth. This process was repeated an arbitrary number of times, with the default being 1000. Once this information was obtained, histograms were made showing the distributions of the sizes of the melt pool’s length, width, and depth. Representative statistical metrics of the distributions were calculated (mean, standard deviation, and coefficient of variance). This work found that at the simulated processing values, the melt pool’s width and depth had a 5.7% variation while the length had a 3.2% variation. Additionally, a tool was constructed to graph a thermal color map representation of the melt pool for specific, arbitrary values of density, specific heat, and conductivity. This tool allowed for more efficient plotting of individual queries of the thermophysical properties. The results that were observed in the research were that values reported in literature vary and this variance can have a significant impact on the simulation. Predictions of the melt pool’s dimensions show that length has a standard deviation of approximately 6 μm, width has a standard deviation of approximately 5 μm, and depth can vary by approximately 3 μm. Considering the mean sizes of length, width, and depth are 185 μm, 88 μm, and 44 μm respectively, such a deviation is significant. This shows that depth, for example, could be more than 10% larger or smaller than expected. This demonstrates that variability in the reported thermophysical properties are not negligible and should be expected to have an influence on the results of the laser powder bed fusion additive manufacturing process. When simulating this process in the future, measures should be taken to account for this discrepancy and the uncertainty involved

Justin Martin↗
NASA NTRS1991

Determination and impact of surface radiative processes for TOGA COARE

Experiments using atmospheric general circulation models have shown that the atmospheric circulation is very sensitive to small changes in sea surface temperature in the tropical western Pacific Ocean warm pool region. The mutual sensitivity of the ocean and the atmosphere in the warm pool region places stringent requirements on models of the coupled ocean atmosphere system. At present, the situation is such that diagnostic studies using available data sets have been unable to balance the surface energy budget in the warm pool region to better than 50 to 80 W/sq m. The Tropical Ocean Global Atmosphere (TOGA) Coupled Ocean Atmosphere Response Experiment (COARE) is an observation and modelling program that aims specifically at the elucidation of the physical process which determine the mean and transient state of the warm pool region and the manner in which the warm pool interacts with the global ocean and atmosphere. This project focuses on one very important aspect of the ocean atmosphere interface component of TOGA COARE, namely the temporal and spatial variability of surface radiative fluxes in the warm pool region.

Curry, Judith A.↗
NASA NTRS2004

Variability of collagen crosslinks: impact of sample collection period

Because of the variability of collagen crosslinks, their use as markers for bone resorption is often criticized. We hypothesized that the variability could be reduced by collecting urine for 24 hours (or longer) instead of using single voids, and by not normalizing to creatinine. Urine samples were collected from 22 healthy subjects during two or more 24-hour periods. Each 24-hour pool and each 2nd void of the day were analyzed for N-telopeptide (NTX), pyridinium (PYD), and deoxypyridinoline (DPD) crosslinks. Data were analyzed by using linear regression. For NTX, R2 for the two, 2nd-void samples (n = 38) was 0.55, whereas R2 for the two 24-hour pools was 0.51 or 0.52, expressed per day or per creatinine. For PYD and DPD, R2 for the 2nd-void samples was 0.26 and 0.18, R2 for the 24-hour pools expressed per day was 0.58 and 0.74, and R2 for the 24-hour pools expressed per creatinine was 0.65 and 0.76, respectively. Regression of the 2nd void and the corresponding 24-hour pool, expressed per day, yielded R2 = 0.19, 0.19, and 0.08, for NTX, PYD, and DPD, respectively (n = 76 each). For the 2nd-void sample and its corresponding 24-hour pool, expressed per creatinine, R2 = 0.24, 0.33, and 0.08, respectively. In a separate study, the coefficient of variation for NTX was reduced (P < 0.05) when data from more than one 24-hour collection were combined. Thus, the variability inherent in crosslink determinations can be reduced by collecting urine for longer periods. In research studies, the high variability of single-void collections, compounded by creatinine normalization, may alter or obscure findings.

Specimen Handling/methods↗
NASA NTRS2005

An Improved Analysis of Forest Carbon Dynamics using Data Assimilation

There are two broad approaches to quantifying landscape C dynamics - by measuring changes in C stocks over time, or by measuring fluxes of C directly. However, these data may be patchy, and have gaps or biases. An alternative approach to generating C budgets has been to use process-based models, constructed to simulate the key processes involved in C exchange. However, the process of model building is arguably subjective, and parameters may be poorly defined. This paper demonstrates why data assimilation (DA) techniques - which combine stock and flux observations with a dynamic model - improve estimates of, and provide insights into, ecosystem carbon (C) exchanges. We use an ensemble Kalman filter (EnKF) to link a series of measurements with a simple box model of C transformations. Measurements were collected at a young ponderosa pine stand in central Oregon over a 3-year period, and include eddy flux and soil C02 efflux data, litterfall collections, stem surveys, root and soil cores, and leaf area index data. The simple C model is a mass balance model with nine unknown parameters, tracking changes in C storage among five pools; foliar, wood and fine root pools in vegetation, and also fresh litter and soil organic matter (SOM) plus coarse woody debris pools. We nested the EnKF within an optimization routine to generate estimates from the data of the unknown parameters and the five initial conditions for the pools. The efficacy of the DA process can be judged by comparing the probability distributions of estimates produced with the EnKF analysis vs. those produced with reduced data or model alone. Using the model alone, estimated net ecosystem exchange of C (NEE)= -251 f 197g Cm-2 over the 3 years, compared with an estimate of -419 f 29gCm-2 when all observations were assimilated into the model. The uncertainty on daily measurements of NEE via eddy fluxes was estimated at 0.5gCm-2 day-1, but the uncertainty on assimilated estimates averaged 0.47 g Cm-2 day-1, and only exceeded 0.5gC m-2 day-1 on days where neither eddy flux nor soil efflux data were available. In generating C budgets, the assimilation process reduced the uncertainties associated with using data or model alone and the forecasts of NEE were statistically unbiased estimates. The results of the analysis emphasize the importance of time series as constraints. Occasional, rare measurements of stocks have limited use in constraining the estimates of other components of the C cycle. Long time series are particularly crucial for improving the analysis of pools with long time constants, such as SOM, woody biomass, and woody debris. Long-running forest stem surveys, and tree ring data, offer a rich resource that could be assimilated to provide an important constraint on C cycling of slow pools. For extending estimates of NEE across regions, DA can play a further important role, by assimilating remote-sensing data into the analysis of C cycles. We show, via sensitivity analysis, how assimilating an estimate of photosynthesis - which might be provided indirectly by remotely sensed data - improves the analysis of NEE.

Williams, Mathew↗
NASA NTRS2019

Operation of a Heat Pipe with Multiple Heat Loads Under Reflux Mode

"Heat pipes are being used on many spacecraft to acquire heat dissipated by the payload and transport the heat to a remote radiator. In instrument-level or spacecraft-level ground testing, many heat pipes are placed in a gravity-driven reflux mode where the condenser is well above the evaporator, resulting in the formation of a liquid pool at the bottom of the heat pipe. If a head load is applied to a site that is in contact with the liquid pool, the generated vapor will flow upward to the condenser and the condensate will fall back to the evaporator due the influence of gravity. Hence, the heat pipe can operate steadily under reflux mode because the heated site always has sufficient liquid supply to sustain the fluid flow. In contrast, when a heat load is applied to a site remote from the liquid pool, the heat pipe will be unable to transfer heat through liquid evaporation unless the heated site has a chance to be in contact with liquid. This can be accomplished by applying an additional heat load to the liquid pool to establish a reflux flow so that the remote site can capture the falling condensate. An experimental investigation was conducted to study the effect of gravity on the thermal performance of a heat pipe under reflux mode with multiple heat loads. An aluminum ammonia heat pipe with internal axial grooves was placed in a vertical position. Cooling was provided to the top of the heat pipe, and heat was applied to three sites below the condenser with various heat distributions. One of the heated sites was above the liquid pool, and two were in direct contact with the liquid pool. Test results showed that when a heat load was applied to either one or both of the lower sites, the heat pipe could run steadily under reflux mode. After a reflux flow had been established, a heat load could be applied to the upper site. If the upper site could capture sufficient liquid falling from the condenser to handle its heat load solely by liquid evaporation, the heat pipe could reach steady operation. Otherwise, the temperature of the upper site would oscillate due to its intermittent contact with the falling liquid. For a given heat load to the upper site, the amplitude of temperature oscillation decreased with an increasing heat load to the lower sites because there was more falling condensate available for the upper site to capture. Moreover, the temperature oscillation disappeared completely when the total heat loads to lower sites exceeded a threshold power, and the threshold power increased with an increasing heat load to the upper site."

Ku, Jentung↗
NASA NTRSDate not supplied

Critical Heat Flux of Liquid Hydrogen, Liquid Methane, and Liquid Oxygen: A Review of Available Data and Predictive Tools

Available experimental data dealing with critical heat flux (CHF) of liquid hydrogen (LH 2 ), liquid methane (LCH 4 ), and liquid oxygen (LO 2 ) in pool and flow boiling are compiled. The compiled data are compared with widely used correlations. Experimental pool boiling CHF data for the aforementioned cryogens are scarce. Based on only 25 data points found in five independent sources, the correlation of Sun and Lienhard (1970) is recommended for predicting the pool CHF of LH 2 . Only two experiments with useful CHF data for the pool boiling of LCH 4 could be found. Four different correlations including the correlation of Lurie and Noyes (1964) can predict the pool boiling CHF of LCH 4 within a factor of two for more than 70% of the data. Furthermore, based on the 19 data points taken from only two available sources, the correlation of Sun and Lienhard (1970) is recommended for the prediction of pool CHF of LO 2 . Flow boiling CHF data for LH 2 could be found in seven experimental studies, five of them from the same source. Based on the 91 data points, it is suggested that the correlation of Katto and Ohno (1984) be used to predict the flow CHF of LH 2 . No useful data could be found for flow boiling CHF of LCH 4 or LO 2 . The available databases for flow boiling of LCH 4 and LO 2 are generally deficient in all boiling regimes. This deficiency is particularly serious with respect to flow boiling.

Multi-Phase Flow↗
NASA NTRS2023

Critical Heat Flux of Liquid Hydrogen, Liquid Methane, and Liquid Oxygen: A Review of Available Data and Predictive Tools

Available experimental data dealing with critical heat flux (CHF) of liquid hydrogen (LH2), liquid methane (LCH4), and liquid oxygen (LO2) in pool and flow boiling are compiled. The compiled data are compared with widely used correlations. Experimental pool boiling CHF data for the aforementioned cryogens are scarce. Based on only 25 data points found in five independent sources, the correlation of Sun and Lienhard (1970) is recommended for predicting the pool CHF of LH2. Only two experiments with useful CHF data for the pool boiling of LCH4 could be found. Four different correlations including the correlation of Lurie and Noyes (1964) can predict the pool boiling CHF of LCH4 within a factor of two for more than 70% of the data. Furthermore, based on the 19 data points taken from only two available sources, the correlation of Sun and Lienhard (1970) is recommended for the prediction of pool CHF of LO2. Flow boiling CHF data for LH2 could be found in seven experimental studies, five of them from the same source. Based on the 91 data points, it is suggested that the correlation of Katto and Ohno (1984) be used to predict the flow CHF of LH2. No useful data could be found for flow boiling CHF of LCH4 or LO2. The available databases for flow boiling of LCH4 and LO2 are generally deficient in all boiling regimes. This deficiency is particularly serious with respect to flow boiling.

Multi-Phase Flow↗
NASA NTRS1978

The production of ultrathin polyimide films for the solar sail program and Large Space Structures Technology (LSST): A feasibility study

Polyimide membranes of a thickness range from under 0.01 micron m to greater than 1 micron m can be produced at an estimated cost of 50 cents per sq m (plus the cost of the polymer). The polymer of interest is dissolved in a solvent which is solube in water. The polymer or casting solution is allowed to flow down an inclined ramp onto a water surface where a pool of floating polymer develops. The solvent dissolves into the water lowering the surface tension of the water on equently, the contact angle of the polymer pool is very low and the edge of the pool is very thin. The solvent dissolves from this thin region too rapidly to be replenished from the bulk of the pool and a solid polymer film forms. Firm formation is rapid and spontaneous and the film spreads out unaided, many feet from the leading edge of the pool. The driving force for this process is the exothermic solution of the organic solvent from the polymer solution into the water.

Forester, R. H.↗
NASA NTRS2000

Radiative-Convective Processes in Regulating Tropical Ocean-Atmosphere

Relationship between sea surface temperature (SST) and cloud/water vapor reveals important information about radiative-climate feedbacks. Many previous studies have found that cloud amount and SST are positively correlated for SST between 28-29.5 C, for SST greater than 29.5 C, cloud amount actually decreases with increasing SST. The breakdown of SST-cloud correlation at 29.5 C was suggested to be related to the formation of localized hot spots with very high SST due to increased solar radiation in regions of strong subsidence forced by convection elsewhere. In this study, the breakdown is related to the radiative cooling in the subsidence regime over the cold pool surrounding the warm pool. We show model and observational evidence that radiative cooling over the cold pool limits the strength of SST-induced tropical circulation. As a result, occurrence of convection is also limited when SST contrast between the warm pool and cold pool is large.

Sui, C.-H.↗
NASA NTRS2003

Liquid Fuels: Pyrolytic Degradation and Fire Spread Behavior as Influenced by Buoyancy

This project was conducted by the Combustion and Emission Control Lab in the Engineering Department at Clark Atlanta University under NASA Grant No. NCC3-707. The work aimed at providing data to supplement the ongoing NASA research activities on flame spread across liquid pools by providing flow visualization and velocity measurements especially in the gas phase and gas-liquid interface. During this investigation, the detailed physics of flame spread across liquid pools was revealed using particle image velocimetry (PIV), 3-dimensional Laser Doppler velocimetry (LDV) and high-speed video imaging system (HSVS). Flow fields (front and side views) of both the liquid and gas phases were visually investigated for the three subflash regimes of flame spread behavior. Some interesting findings obtained from the front and side views on flame spread across butanol pools are presented. PIV results showed the size of the transient vortex in the liquid phase near the flame front varied with the initial pool temperature. The transient vortex ahead of the flame front in the gas phase was, for the first time, clearly observed located just within 0-3 mm above the liquid surface and its size was dependent on the initial pool temperature. We calculated the flow velocity at 1 mm below the liquid surface near the flame front and inferred the generation mechanism of the vortex in the gas phase. Finally, after comparison of the flow velocity of the liquid surface and the flame spread rate, a reasonable explanation to the formation mechanism of the pulsating characteristic was proposed. This explanation is compatible with the previous numerical calculations and deductions.

Ross, Howard D.↗
NASA NTRS2015

Enhanced Pacific Ocean Sea Surface Temperature and Its Relation to Typhoon Haiyan

Typhoon Haiyan, which devastated the Visayan Islands in the Philippines on November 8, 2013 was recorded as the strongest typhoon ever-observed using satellite data. Typhoons in the region usually originate from the mid-Pacific region that includes the Warm Pool, which is regarded as the warmest ocean surface region globally. Two study areas were considered: one in the Warm Pool Region and the other in the West Pacific Region near the Philippines. Among the most important factors that affect the strength of a typhoon are sea surface temperature (SST) and water vapor. It is remarkable that in November 2013 the average SST in the Warm Pool Region was the highest observed during the 1981 to 2014 period while that of the West Pacific Region was among the highest as well. Moreover, the increasing trend in SST was around 0.20C per decade in the warm pool region and even higher at 0.23C per decade in the West Pacific region. The yearly minimum SST has also been increasing suggesting that the temperature of the ocean mixed layer is also increasing. Further analysis indicated that water vapor, clouds, winds and sea level pressure for the same period did not reveal strong signals associated with the 2013 event. The SST is shown to be well-correlated with wind strength of historically strong typhoons in the country and the observed trends in SST suggest that extremely destructive typhoons like Haiyan are likely to occur in the future.

warm pool↗
NASA NTRS1977

Impacts and Benefits of a Satellite Power System on the Electric Utility Industry

The purpose of this limited study was to investigate six specific issues associated with interfacing a Satellite Power System (5 GW) with large (by present standards) terrestrial power pools to a depth sufficient to determine if certain interface problems and/or benefits exist and what future studies of these problems are required. The issues investigated are as follows: (1) Stability of Power Pools Containing a 5 GWe SPS; (2) Extra Reserve Margin Required to Maintain the Reliability of Power Pools Containing a 5 GWe SPS; (3) Use of the SPS in Load Following Service (i.e. in two independent pools whose times of peak demand differ by three hours); (4) Ownership of the SPS and its effect on SPS Usage and Utility Costs; (5) Utility Sharing of SPS related RD and D Costs; (6) Utility Liability for SPS Related Hazards.

Winer, B. M.↗
NASA NTRS1987

Examination of the physical processes associated with the keyhole region of variable polarity plasma arc welds in aluminum alloy 2219

The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. This study examined the effects of oxide, halide, and sulfate additions to the weld plate on the keyhole and the weld pool. Changes in both the arc plasma character and the bead morphology were correlated to the chemical environment of the weld. Pool behavior was observed by adding flow markers to actual VPPA welds. A low temperature analog to the welding process was developed. The results of the study indicate that oxygen, even at low partial pressures, can disrupt the stable keyhole and weld pool. The results also indicate that the Marangoni surface tension driven flows dominate the weld pool over the range of welding currents studied.

Walsh, Daniel W.↗
NASA NTRS1991

Response of vegetation indices to changes in three measures of leaf water stress

The responses of vegetation indices to changes in water stress were evaluated in two separate laboratory experiments. In one experiment the normalized difference vegetation index (NDVI), the near-IR to red ratio (near-IR/red), the Infrared Index (II), and the Moisture Stress Index (MSI) were more highly correlated to leaf water potential in lodgepole pine branches than were the Leaf Water Content Index (LWCI), the mid-IR ratio (Mid-IR), or any of the single Thematic Mapper (TM) bands. In the other experiment, these six indices and the TM Tasseled Cap brightness, greenness, and wetness indices responded to changes in leaf relative water content (RWC) differently than they responded to changes in leaf water content (WC) of three plant species, and the responses were dependent on how experimental replicates were pooled. With no pooling, the LWCI was the most highly correlated index to both RWC and WC among replications, followed by the II, MSI, and wetness. Only the LWCI was highly correlated to RWC and WC when replications were pooled within species. With among species pooling the LWCI was the only index highly correlated with RWC, while the II, MSI, Mid-IR, and wetness were most highly correlated with WC.

Cohen, Warren B.↗
NASA NTRS1994

A comparison between general circulation model simulations using two sea surface temperature datasets for January 1979

Simulations with the UCLA atmospheric general circulation model (AGCM) using two different global sea surface temperature (SST) datasets for January 1979 are compared. One of these datasets is based on Comprehensive Ocean-Atmosphere Data Set (COADS) (SSTs) at locations where there are ship reports, and climatology elsewhere; the other is derived from measurements by instruments onboard NOAA satellites. In the former dataset (COADS SST), data are concentrated along shipping routes in the Northern Hemisphere; in the latter dataset High Resolution Infrared Sounder (HIRS SST), data cover the global domain. Ensembles of five 30-day mean fields are obtained from integrations performed in the perpetual-January mode. The results are presented as anomalies, that is, departures of each ensemble mean from that produced in a control simulation with climatological SSTs. Large differences are found between the anomalies obtained using COADS and HIRS SSTs, even in the Northern Hemisphere where the datasets are most similar to each other. The internal variability of the circulation in the control simulation and the simulated atmospheric response to anomalous forcings appear to be linked in that the pattern of geopotential height anomalies obtained using COADS SSTs resembles the first empirical orthogonal function (EOF 1) in the control simulation. The corresponding pattern obtained using HIRS SSTs is substantially different and somewhat resembles EOF 2 in the sector from central North America to central Asia. To gain insight into the reasons for these results, three additional simulations are carried out with SST anomalies confined to regions where COADS SSTs are substantially warmer than HIRS SSTs. The regions correspond to warm pools in the northwest and northeast Pacific, and the northwest Atlantic. These warm pools tend to produce positive geopotential height anomalies in the northeastern part of the corresponding oceans. Both warm pools in the Pacific produce large-scale circulation anomalies with a pattern that resembles that obtained using COADS SSTs as well as EOF 1 of the control simulation; the warm pool in the Atlantic does not. These results suggest that the differences obtained with COADS SSTs and HIRS SSTs are mostly due to the differences in the datasets over the northern Pacific. There was a blocking episode near Greenland in late January 1979. Both simulations with warm SST anomalies over the northwest and northeast Pacific show a tendency toward increased incidence of North Atlantic blocking; the simulation with warm SST anomalies over the northwest Atlantic shows a tendency toward decreased incidence. These results suggest that features in both SST datasets that do not have a counterpart in the other dataset contribute signficantly to the differences between the simulated and observed fields. The results of this study imply that uncertainties in current SST distributions for the world oceans can be as important as the SST anomalies themselves in terms of their impact on the atmospheric circulation. Caution should be exercised, therefore, when linking anomalous circulation and SST patterns, especially in long-range prediction.

Ose, Tomoaki↗
NASA NTRS1998

An Assessment of Molten Metal Detachment Hazards for Electron Beam Welding in the Space Environment: Analysis and Test Results

Conditions under which molten metal detachments might occur in a space welding environment are analyzed. A weld pool detachment parameter specifying conditions for pool detachment by impact is derived and corroborated by experimental evidence. Impact detachment for the pool is unlikely. Impact detachment for a drop of metal on the end of the weld wire may be possible under extreme conditions. Other potential causes of molten metal detachment considered, vaporization pressure forces and wire flickout from the pool, did not appear to present significant detachment threats.

Nunes, A. C., Jr.↗
NASA NTRS1999

Flame Spread Across Liquids: Experimental Results

The goal of our research on flame spread across a pool of liquid fuel is the quantitative identification of the mechanisms that control the rate and nature of flame spread when the initial temperature of the liquid pool is below the fuel's flash point temperature. Besides numerous experiments in drop towers and 1 g laboratories, we have flown five microgravity (mu-g) experiments on sounding rockets. As described in earlier papers, the first three flights examined the effect of forced opposed airflow over a 2.5 cm deep x 2 cm wide x 30 cm long pool of 1-butanol in mu-g. It was found that the flame spread is much slower and steadier than in 1 g where flame spread has a pulsating character. It was speculated that the flame spread in mu-g resembled the character of pseudo-uniform spread in 1 g; Ito et al later confirmed this conclusively in 1 g experiments. Much of the mu-g flame is also farther from the surface, dimmer, and with less soot, when compared to the 1 g flame. Three-dimensional liquid-phase flow patterns that control the liquid preheating were discovered in both 1 g and mu-g. Our numerical model, restricted to two dimensions, had predicted faster, pulsating flame spread in mu-g for opposed airflow. In examining the differences in the dimensionality of the model and experiment, it was noted that the experiment allowed gas expansion in the lateral direction (across the width of the pool), for which the model could not account. Such lateral expansion could reduce the expansion in the forward and upward directions. Because only these latter directions could be modeled, it was decided to artificially reduce the gas thermal expansion in the predictions. When this was done, satisfactory agreement could be obtained between the predicted and observed spread rates and the steadiness of the spread in microgravity. In 1 g, however, the predicted flame spread character also changed to pseudo-uniform, which disagreed with our 1 g experiments where the spread is pulsating. It was then speculated that gas-phase buoyant flow might oppose the lateral gas expansion, so that the 1 g experiments retained their pulsating flame spread character. If this speculation was valid, a difference in lateral gas expansion should be observable when comparing 1 g and mu-g experiments. Specifically, it was anticipated that greater flow divergence caused by lateral expansion would be measured in mu-g in the absence of a buoyant flow directed towards the flame.

Ross, H. D.↗
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.↗