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Report describes development of next-generation control system for variable-polarity plasma arc (VPPA) welding. When fully developed, system expected to incorporate advanced sensors and adaptive control of position of and current in welding torch.
TAZ-8A exhibits high strength at temperatures as high as 1,400 degrees F (760 degrees C) and resistance to oxidation; also exhibits excellent cyclic shock resistance between 600 and 2,000 degrees F (316 and 1,093 degrees C) and superplasticity at 1,800 degrees F (982 degrees C). Converts into fine powder and then flame-, plasma-, arc-, or wire-sprayed onto inexpensive steel substrate. Surface treatment with this alloy prolongs service life and reduces costs.
An investigation into the heat sink effects due to weldment irregularities and fixtures used in the variable polarity plasma arc (VPPA) process was conducted. A basic two-dimensional model was created to represent the net heat sink effect of surplus material using Duhamel's theorem to superpose the effects of an infinite number of line heat sinks of variable strength. Parameters were identified that influence the importance of heat sink effects. A characteristic length, proportional to the thermal diffusivity of the weldment material divided by the weld torch travel rate, correlated with heat sinking observations. Four tests were performed on 2219-T87 aluminum plates to which blocks of excess material were mounted in order to demonstrate heat sink effects. Although the basic model overpredicted these effects, it correctly indicated the trends shown in the experimental study and is judged worth further refinement.
An investigation into the heat sink effects due to weldment irregularities and fixtures used in the variable polarity plasma arc (VPPA) process was conducted. A basic two-dimensional model was created to represent the net heat sink effect of surplus material using Duhamel's theorem to superpose the effects of an infinite number of line heat sinks of variable strength. Parameters were identified that influence the importance of heat sink effects. A characteristic length, proportional to the thermal diffusivity of the weldment material divided by the weld torch travel rate, correlated with heat sinking observations. Four tests were performed on 2219-T87 aluminum plates to which blocks of excess material were mounted in order to demonstrate heat sink effects. Although the basic model overpredicted these effects, it correctly indicated the trends shown in the experimental study and is judged worth further refinement.
Welding automation is the key to two major development programs to improve quality and reduce the cost of manufacturing space hardware currently undertaken by the Materials and Processes Laboratory of the NASA Marshall Space Flight Center. Variable polarity plasma arc welding has demonstrated its effectiveness on class 1 aluminum welding in external tank production. More than three miles of welds were completed without an internal defect. Much of this success can be credited to automation developments which stabilize the process. Robotic manipulation technology is under development for automation of welds on the Space Shuttle's main engines utilizing pathfinder systems in development of tooling and sensors for the production applications. The overall approach to welding automation development undertaken is outlined. Advanced sensors and control systems methodologies are described that combine to make aerospace quality welds with a minimum of dependence on operator skill.
Proposed welding technique combines best features of metal (other than tungsten)/inert-gas welding, plasma arc welding, and tungsten/inert-gas welding. Advantages include: wire fed to weld joint preheated, therefore fed at high speed without spattering; high-frequency energy does not have to be supplied to workpiece to initiate welding; size of arc gap not critical, power-supply control circuit adjusts voltage across gap to compensate for changes; only low gas-flow rate needed; welding electrode replaced easily as prefabricated assembly; external wire-feeding manipulator not needed; and welding process relatively forgiving of operator error.
Simple modification yields welds of better quality. Reed valve halves fluctuations in pressure in back-purge chamber attached to workpiece undergoing keyhole plasma arc welding. Identical to one used in fuel system of two-cycle gasoline engine. Backbead smoother, and weld penetrates more uniformly.
Report describes theoretical and experimental study of absorption of heat by metal blocks in contact with metal plate while plate subjected to variable-polarity plasma-arc (VPPA) welding. Purpose of study to contribute to development of comprehensive mathematical model of temperature in weld region. Also relevant to welding of thin sheets of metal to thick blocks of metal, heat treatment of metals, and hotspots in engines.
Trailing shield ensures layer of inert gas covers hot, newly formed bead between two tubes or pipes joined by plasma arc welding. Inert gas protects weld bead from oxidation by air until cooler and less vulnerable to oxidation. Intended for use on nickel-base alloy pipes, on which weld beads remain hot enough to oxidize after primary inert-gas purge from welding-torch cup has passed.
The development of a model for prediction of heat sink effects associated with the Variable Polarity Plasma Arc (VPPA) Welding Process is discussed. The long term goal of this modeling is to provide means for assessing potential heat sink effects and, eventually, to provide indications as to changes in the welding process that could be used to compensate for these effects and maintain the desired weld quality. In addition to the development of a theoretical model, a brief experimental investigation was conducted to demonstrate heat sink effects and to provide an indication of the accuracy of the model.
A composite flexible blanket insulation (CFBI) system considered for use as a thermal protection system for space vehicles is described. This flexible composite insulation system consists of an outer layer of silicon carbide fabric, followed by alumina mat insulation, and alternating layers of aluminized polyimide film and aluminoborosilicate scrim fabric. A potential application of this composite insulation would be as a thermal protection system for the aerobrake of the aeroassist space transfer vehicle (ASTV). It would also apply to other space vehicles subject to high convective and radiative heating during atmospheric entry. The thermal performance of this composite insulation as exposed to a simulated atmospheric entry environment in a plasma arc test facility is described. Other thermophysical properties which affect the thermal response of this composite insulation is included. It shows that this composite insulation is effective as a thermal protection system at total heating rates up to 30.6 W/sq cm.
Hardware development of the Shuttle Entry Data System (SEADS) is described. The system consists of an array of fourteen pressure ports, installed in an Orbiter nose cap, which, when coupled with existing fuselage mounted static pressure ports permits computation of entry flight parameters. Elements of the system that are described include the following: (1) penetration assemblies to place pressure port openings at the surface of the nose cap; (2) pressure tubes to transmit the surface pressure to transducers; (3) support posts or manifolds to provide support for, and reduce the length of, the individual pressure tubes; (4) insulation for the manifolds; and (5) a SEADS nose cap. Design, analyses, and tests to develop and certify design for flight are described. Specific tests include plasma arc exposure, radiant thermal, vibration, and structural. Volume one summarizes highlights of the program, particularly as they relate to the final design of SEADS. Volume two summarizes all of the Vought responsible activities in essentially a chronological order.
Hardware development of the Shuttle Entry Air Data System (SEADS) is described. The system consists of an array of fourteen pressure ports, installed in an Orbiter nose cap, which, when coupled with existing fuselage mounted static pressure ports permits computation of entry flight parameters. Elements of the system that are described include the following: (1) penetration assemblies to place pressure port openings at the surface of the nose cap; (2) pressure tubes to transmit the surface pressure to transducers; (3) support posts or manifolds to provide support for, and reduce the length of, the individual pressure tubes; (4) insulation for the manifolds; and (5) a SEADS nose cap. Design, analyses, and tests to develop and certify design for flight are described. Specific tests included plasma arc exposure, radiant thermal, vibration, and structural. Volume one summarizes highlights of the program, particularly as they relate to the final design of SEADS. Volume two summarizes all of the Vought responsible activities in essentially a chronological order.
Theoretical and experimental studies of heat-tranfer in a space environment are discussed in reviews and reports. Topics addressed include a small-scale two-phase thermosiphon to cool high-power electronics, a low-pressure-drop heat exchanger with integral heat pipe, an analysis of the thermal performance of heat-pipe radiators, measurements of temperature and concentration fields in a rectangular heat pipe, and a simplified aerothermal heating method for axisymmetric blunt bodies. Consideration is given to entropy production in a shock wave, bubble-slug transition in a two-phase liquid-gas flow under microgravity, plasma arc welding under normal and zero gravity, the Microgravity Thaw Experiment, the flow of a thin film on stationary and rotating disks, an advanced ceramic fabric body-mounted radiator for Space Station Freedom phase 0 design, and lunar radiators with specular reflectors.
The application is described of a weld programming algorithm for vertical-up welding, which is frequently desired for variable polarity plasma arc welding (VPPAW). The Basic algorithm performs three tasks simultaneously: control of the robotic mechanism so that proper torch motion is achieved while minimizing the sum-of-squares of joint displacement; control of the torch while the part is maintained in a desirable orientation; and control of the wire feed mechanism location with respect to the moving welding torch. Also presented is a modification of this algorithm which permits it to be used for vertical-up welding. The details of this modification are discussed and simulation examples are provided for illustration and verification.
Described here is the thermal performance of rigid and flexible thermal protection systems considered for potential use in future Aeroassist Space Transfer Vehicles. The thermal response of these materials subjected to aeroconvective heating from a plasma arc is described. Properties that were measured included the thermal conductivity of both rigid and flexible insulations at various temperatures and pressures and the emissivity of the fabrics used in the flexible insulations. The results from computerized thermal analysis models describing the thermal response of these materials subjected to flight conditions are included.
The present conference discusses such topics in spacecraft welding as the NASA Long Duration Exposure Facility's evidence on material properties degradation, EVA/telerobotic construction techniques, welding of the superfluid helium on-orbit transfer flight demonstration tanks and hardware, electron-beam welding of aerospace vehicles, variable-polarity plasma arc keyhole welding of Al, aircraft experiments of low-gravity fusion welding, flash-butt welding of Al alloys, and a computer-aided handbook for space welding fabrication. Also discussed are the welded nozzle extension for Ariane launch vehicles, the existence of on-orbit cold-welding, structural materials performance in long-term space service, high-strength lightweight alloys, steels, and heat-resistant alloys for aerospace welded structures, the NASA-Goddard satellite repair program, and the uses of explosion welding and cutting in aerospace engineering.
Optical-emission spectrometric apparatus used to monitor variable-polarity plasma arc welding of aluminum alloys. Spectrometer incorporated into control system to ensure quality of weld because in keyhole, arc fully penetrates weld joint and impurities flushed out. Apparatus helps ensure high quality of weld by monitoring such contaminants as oxygen and hydrogen in shield gas, detecting inadequate flow of shield gas, and sensing changes in temperature of arc with changes in arc current and voltage.