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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

The variable polarity plasma arc welding process: Characteristics and performance

Significant advantages of the Variable Polarity Plasma Arc (VPPA) Welding Process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. The power distribution was analyzed for an argon plasma gas flow constituting the fluid in the VPPA Welding Process. The major heat loss at the torch nozzle is convective heat transfer; in the space between the outlet of the nozzle and the workpiece; radiative heat transfer; and in the keyhole in the workpiece, convective heat transfer. The power absorbed at the workpiece produces the molten puddle that solidifies into the weld bead. Crown and root widths, and crown and root heights of the weld bead are predicted. The basis is provided for an algorithm for automatic control of VPPA welding machine parameters to obtain desired weld bead dimensions.

Hung, R. J.↗
NASA NTRS1992

A more accurate nonequilibrium air radiation code - NEQAIR second generation

Two experiments, one an equilibrium flow in a plasma torch at Stanford, the other a nonequilibrium flow in a SDIO/IST Bow-Shock-Ultra-Violet missile flight, have provided the basis for modifying, enhancing, and testing the well-known radiation code, NEQAIR. The original code, herein termed NEQAIR1, lacked computational efficiency, accurate data for some species and the flexibility to handle a variety of species. The modified code, herein termed NEQAIR2, incorporates recent findings in the spectroscopic and radiation models. It can handle any number of species and radiative bands in a gas whose thermodynamic state can be described by up to four temperatures. It provides a new capability of computing very fine spectra in a reasonable CPU time, while including transport phenomena along the line of sight and the characteristics of instruments that were used in the measurements. Such a new tool should allow more accurate testing and diagnosis of the different physical models used in numerical simulations of radiating, low density, high energy flows.

Moreau, Stephane↗
NASA NTRS1993

Width Criterion For Weld-Seam-Tracking Data

Image-processing algorithm in "through-torch-vision" (T3V) system developed to guide gas/tungsten arc welding robot along weld seam modified, according to proposal, reducing incidence of inaccurate tracking of weld seam. Developmental system intended to provide closed-loop control of motion of welding robot along weld seam on basis of lines in T3V image identified by use of image-processing algorithm and assumed to coincide with edges of weld seam. Use of width criterion prevents tracking of many false pairs of lines, with consequent decrease in incidence of inaccurate tracking and increase in confidence in weld-tracking capability of robotic welding system.

Lincir, Mark R.↗
NASA NTRS1992

Arc-cathode interaction study

Insufficient electrode life and uncertainties in that life are major problems hampering the development in many plasma application areas which make use of plasma torches, arc heaters, and arc jet thrusters. In spite of a considerable amount of work published dealing with arc-cathode phenomena, our present understanding is still incomplete because different physical phenomena dominate for different combinations of experimental parameters. The objective of our present research project is to gain a better understanding of the behavior of arc-cathode surface interaction over a wide range of parameters, and furthermore to develop guidelines for better thermal design of the electrode and the selection of materials. This report will present the research results and progress obtained on the arc-cathode interaction studies at the University of Minnesota. It includes results which have been obtained under programs other than the NASA funded program. Some of the results have been submitted in an informal interim progress report, and all of the results have been presented in a seminar during a visit to the NASA Lewis Research Center on October 16, 1992.

Zhou, X.↗
NASA NTRS1992

Instruction manual for UTEP weld gas hydrogen detector

The instrument described in this manual was developed at the University of Texas at El Paso under contract from the National Aeronautics and Space Administration Marshall Space Flight Center. The instrument has been used to detect hydrogen in the shielding gas of Variable Polarity Plasma Arc (VPPA) welds at concentrations of less than 100 ppm. The instrument makes measurements in real time during the welding operation and provides the operator with an easily readable graphic display of the present level of hydrogen in the arc as well as the level of hydrogen over the past approximately five minutes. In this way the welder can not only tell if the present level of hydrogen is excessive, but can see what changes in weld parameters have done to the level of hydrogen. The welder can set the level of hydrogen that is considered critical and the instrument display will indicate when that level has been exceeded. All detection is from the torch side. All needed equipment is supplied by the developer except for an IBM PC compatible computer which must be supplied by the user. Source code is supplied in this manual so that the user can modify the control program as desired.

Mcclure, John↗
NASA NTRS1993

Characterization and durability testing of plasma-sprayed zirconia-yttria and hafnia-yttria thermal barrier coatings. Part 1: Effect of spray parameters on the performance of several lots of partially stabilized zirconia-yttria powder

Initial experiments conducted on thermal barrier coatings prepared in the newly upgraded research plasma spray facility and the burner rig test facilities are discussed. Part 1 discusses experiments which establish the spray parameters for three baseline zirconia-yttria coatings. The quality of five similar coating lots was judged primarily by their response to burner rig exposure supplemented by data from other sources such as specimen characterizations and thermal diffusivity measurements. After allowing for burner rig variability, although there appears to be an optimum density (i.e., optimum microstructure) for maximum burner rig life, the distribution tends to be rather broad about the maximum. In Part 2, new hafnia-yttria-based coatings were evaluated against both baseline and alternate zirconia-yttria coatings. The hafnia-yttria coatings and the zirconia-yttria coatings that were prepared by an alternate powder vendor were very sensitive to plasma spray parameters, in that high-quality coatings were only obtained when certain parameters were employed. The reasons for this important observation are not understood. Also not understood is that the first of two replicate specimens sprayed for Part 1 consistently performed better than the second specimen. Subsequent experiments did not display this spray order affect, possibly because a chiller was installed in the torch cooling water circuit. Also, large changes in coating density were observed after switching to a new lot of electrodes. Analyses of these findings were made possible, in part, because of the development of a sensitive density measurement technique described herein in detail. The measured thermal diffusivities did not display the expected strong relationship with porosity. This surprising result was believed to have been caused by increased microcracking of the denser coatings on the stainless steel substrates.

Miller, Robert A.↗
NASA NTRS1993

Adaptive weld control for high-integrity welding applications

An advanced adaptive control weld system for high-integrity welding applications is presented. The system consists of a state-of-the-art weld control subsystem, motion control subsystem, and sensor subsystem which closes the loop on the process. The adaptive control subsystem (ACS), which is required to totally close the loop on weld process control, consists of a multiprocessor system, data acquisition hardware, and three welding sensors which provide measurements from all areas around the torch in real time. The ACS acquires all 'measurables' and feeds offset trims back into the weld control and motion control subsystems to modify the 'controllables' in order to maintain a previously defined weld quality.

Powell, Bradley W.↗
NASA NTRS1993

Design and fabrication of a hydrogen/oxygen thrust chamber assembly

The combustion system for the Advance Expander Test Bed engine consists of a thrust mount, an injector with a H2-O2 torch igniter, a combustion chamber, and a conical nozzle extension. These components constitute the thrust chamber assembly. The design, fabrication, and testing of these components are described in detail.

Hernacki, Thomas R.↗
NASA NTRS1994

Inert-Gas Diffuser For Plasma Or Arc Welding

Inert-gas diffuser provides protective gas cover for weld bead as it cools. Follows welding torch, maintaining continuous flow of argon over newly formed joint and prevents it from oxidizing. Helps to ensure welds of consistently high quality. Devised for plasma arc keyhole welding of plates of 0.25-in. or greater thickness, also used in tungsten/inert-gas and other plasma or arc welding processes.

Gilbert, Jeffrey L.↗
NASA NTRS1994

Robotic Tool Changer For Automated Welding

Prototype robotic tool changer for automated welding system eliminates need for most manual tool setups and attendant problems: operates rapidly, always chooses designated tool, maneuvers tip of welding torch or other tool in correct position, and reliably connects water, gas, welding wire, high-voltage electrical signals, and ground. Also loads tools other than those for welding. Intended for use in robotic work cell producing all good parts, no rejects. In production, robot welds part, tests for flaws, and reworks as necessary before releasing it.

Gilbert, Jeffrey L.↗
NASA NTRS1994

Apparatus For Metal/Inert-Gas Welding In Vacuum

Metal/inert-gas welding-torch assembly operates in vacuum. Plasma generated in interior chamber and focused onto workpiece in vacuum. Pinch rollers feed wire to weld puddle. Controlled flow of plasma reduces dispersal in vacuum, preventing extinction.

Stocks, C. O.↗
NASA NTRS1994

Rugged Preheaters For Vacuum Plasma Spraying

Electric preheater units built to ensure large workpieces to be coated with metals by vacuum plasma spraying heated uniformly to requisite high temperatures by time plasma torch arrives. Units similar to electrical-resistance ribbon heaters in toasters and in some small portable electric "space" heaters. Nichrome resistance-heating ribbons wrapped around ceramic insulating spools on rings and on plates. Round workpiece placed in middle of ring preheater. Plate preheaters stacked as needed near workpiece.

Woodford, William H.↗
NASA NTRS1993

Mixing and unmixedness in plasma jets 1: Near-field analysis

The flow characteristics in the near-field of a plasma jet are simulated with a two-fluid model. This model accounts for both gradient-diffusion mixing and uni-directional sifting motion resulting from pressure-gradient-body-force imbalance. This latter mechanism is believed to be responsible for the umixedness observed in plasma jets. The unmixedness is considered to be essentially a Rayleigh-Taylor kind instability. Transport equations are solved for the individual plasma and ambient gas velocities, temperatures and volume fractions. Empirical relations are employed for the interface transfers of mass, momentum and heat. The empirical coefficients are first established by comparison of predictions with available experimental data for shear flows. The model is then applied to an Argon plasma jet ejecting into stagnant air. The predicted results show the significant build-up of unmixed air within the plasma gas, even relatively far downstream of the torch. By adjusting the inlet condition, the model adequately reproduces the experimental data.

Ilegbusi, Olusegun J.↗
NASA NTRS1994

Plasma heating for containerless and microgravity materials processing

A method for plasma heating of levitated samples to be used in containerless microgravity processing is disclosed. A sample is levitated by electrostatic, electromagnetic, aerodynamic, or acoustic systems, as is appropriate for the physical properties of the particular sample. The sample is heated by a plasma torch at atmospheric pressure. A ground plate is provided to help direct the plasma towards the sample. In addition, Helmholtz coils are provided to produce a magnetic field that can be used to spiral the plasma around the sample. The plasma heating system is oriented such that it does not interfere with the levitation system.

Leung, Emily W.↗
NASA NTRS1995

Nonchamber, Root-Side, Inert-Gas Purging During Welding

Improved apparatus distributes inert gas to protect against oxidation on root side of weld during welding and after welding while joint remains hot. Simple and lightweight; readily moved along weld path in synchronism with torch. Because it concentrates inert gas where needed, consumes gas at relatively low rate, and not necessary to monitor oxygen content of protective atmosphere. Apparatus does not obscure view of root side of weld. Used for full-penetration plasma-arc welding of such reactive metals as aluminum/lithium alloys and titanium.

Mcgee, William F.↗
NASA NTRS1995

Process-Information Display Panel For Welder's Visor

Head-up display (HUD) unit mounted in welder's visor or helmet provides process information in real time. Display enables welder to gain greater awareness of effects of welding while controlling welding process in usual way(s) by use of foot pedal, voice command, and/or manipulation of welding torch. Possible to avoid need for every new welder on job to solve same problems solved by other welders. Graphical display presented to welder, adjacent to normal field of view through visor. Beneficial in supporting and enhancing continued practice of manual arc welding. Valuable in industries that invest millions of technician-hours each year in manual arc welding for variety of products.

Russell, Carolyn↗
NASA NTRS1995

Automated data acquisition technology development:Automated modeling and control development

This report documents the completion of, and improvements made to, the software developed for automated data acquisition and automated modeling and control development on the Texas Micro rackmounted PC's. This research was initiated because a need was identified by the Metal Processing Branch of NASA Marshall Space Flight Center for a mobile data acquisition and data analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC based system was chosen. The Welding Measurement System (WMS), is a dedicated instrument strickly for use of data acquisition and data analysis. In addition to the data acquisition functions described in this thesis, WMS also supports many functions associated with process control. The hardware and software requirements for an automated acquisition system for welding process parameters, welding equipment checkout, and welding process modeling were determined in 1992. From these recommendations, NASA purchased the necessary hardware and software. The new welding acquisition system is designed to collect welding parameter data and perform analysis to determine the voltage versus current arc-length relationship for VPPA welding. Once the results of this analysis are obtained, they can then be used to develop a RAIL function to control welding startup and shutdown without torch crashing.

Romine, Peter L.↗