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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.
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.
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.
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.
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.
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.
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.
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.
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.
Carbon monoxide and oxygen ignition boundaries were determined in a spark torch igniter as a function of propellant inlet temperatures. The oxygen temperature was varied from ambient to -258 F, and the carbon monoxide temperature was varied from ambient to -241 F. With the oxygen and carbon monoxide at -253 F and -219 F, respectively, they successfully ignited between mixture ratios of 2.42 and 3.10. Analysis of the results indicated that the lower ignition boundary was more sensitive to oxygen temperature than to carbon monoxide temperature. Another series of tests was performed in a small simulated rocket engine with oxygen at -197 F and carbon monoxide at -193 F. An oxygen/hydrogen flame was used to initiate combustion of the oxygen and carbon monoxide. Tests performed at the optimum operating mixture ratio of 0.55 obtained steady-state combustion in every test.
The pre-main sequence star V536 Aql, classified as a K7 classical T Tauri star by Cohen & Kuhi has been resolved, by high angular resolution near-infrared speckle observations, as a close binary (0.52 sec separation at 17 deg) surrounded by extended structures. These structures seen, both in the July 1993 and April 1994 observations, are not at the same position in the reconstructed image and do not present exactly the same shape at both times. Although it is unlikely that the presence of these structures is due to seeing calibration problems, the exact shape might be affected by it. We cannot presently make a final interpretation of the observations but can formulate different possibilities: the 'circumstellar' material seen in our images can be an independent cloud, or simply gas or dust, in front of the system on our line of sight, but close enough to still be illuminated by the binary; this material may be 'by chance' there or be a remnant of the material in which the star was born. We propose a model to explain the position variation of the extended structures. New observations are under reduction and should help to determine the exact value of this motion. At their distance from the star, motions of the extended matter would correspond to velocities much higher than the Kepler velocities. To explain this, we have developed a model based on a 'torch-light' effect. The possibility that the observed elongated structures belong to a circumstellar or circumbinary disk are discussed.
A new velocity measurement instrument for luminous flows was developed by Science Research Laboratory for NASA. The SIEVE (Segmented Image Emission VElocimeter) instrument uses broadband light emitted by the flow for the velocity measurement. This differs from other velocimetry techniques in that it does not depend on laser illumination and/or light scattering from particles in the flow. The SIEVE is a passive, non-intrusive diagnostic. By moving and adjusting the imaging optics, the SIEVE can provide three-dimensional mapping of a flow field and determine turbulence scale size. A SIEVE instrument was demonstrated on an illuminated rotating disk to evaluate instrument response and noise and on an oxy-acetylene torch to measure flame velocities. The luminous flow in rocket combustors and plumes is an ideal subject for the SIEVE velocity measurement technique.
This report describes progress during the second year of our research program on Infrared Signature Masking by Air Plasmas at Stanford University. This program is intended to investigate the masking of infrared signatures by the air plasma formed behind the bow shock of high velocity missiles. Our previous annual report described spectral measurements and modeling of the radiation emitted between 3.2 and 5.5 microns by an atmospheric pressure air plasma in chemical and thermal equilibrium at a temperature of approximately 3100 K. One of our goals was to examine the spectral emission of secondary species such as water vapor or carbon dioxide. The cold air stream injected in the plasma torch contained approximately 330 parts per million Of CO2, which is the natural CO2 concentration in atmospheric air at room temperature, and a small amount of water vapor with an estimated mole fraction of 3.8 x 10(exp -4). As can be seen from Figure 1, it was found that the measured spectrum exhibited intense spectral features due to the fundamental rovibrational bands of NO at 4.9 - 5.5 microns and the V(3) band of CO2 (antisymmetric stretch) at 4.2-4.8 microns. These observations confirmed the well-known fact that infrared signatures between 4.15 - 5.5 microns can be masked by radiative emission in the interceptor's bow-shock. Figure I also suggested that the range 3.2 - 4.15 microns did not contain any significant emission features (lines or continuum) that could mask IR signatures. However, the signal-to-noise level, close to one in that range, precluded definite conclusions. Thus, in an effort to further investigate the spectral emission in the range of interest to signature masking problem, new measurements were made with a higher signal-to-noise ratio and an extended wavelength range.
Detailed measurements and modeling of the spectral emission of an atmospheric pressure air plasma at temperatures up to -3400 K have been made. The cold gas injected in the plasma torch contained an estimated mole fraction of water vapor of approximately 4.5 x 10(exp -3) and an estimated carbon dioxide mole fraction of approximately 3.3 x 10(exp -4). Under these conditions, the minimum level of air plasma emission is found to be between 3.9 and 4.15 microns. Outside this narrow region, significant spectral emission is detected that can be attributed to the fundamental and overtone bands of NO and OH, and to the v(sub 3) and the (v(sub 1)+v(sub 3)) bands Of CO2. Special attention was paid to the effects of ambient air absorption in the optical path between the plasma and the detector. Excellent quantitative agreement is obtained between the measured and simulated spectra, which are both on absolute intensity scales, thus lending confidence in the radiation models incorporated into NEQAIR2-IR over the course of this research program.
A hybrid infrared-hot gas heat source has been developed and tested for the NASA Langley Tow Placement Facility. The IR heat source provides supplemental heat to the nip region. The additional heat is intended to reduce the need for conduction heating by the compaction roller, which causes (he roller to stick to the panel surface. Initial bench scale testing was performed to identify the most effective means of focusing IR energy into the nip region. A compact lamp and reflector that placed the lamp as close to the nip point as possible was found to deliver the highest heat flux in the nip region. A prototype heater was installed on the NASA Langley tow placement robot. Panels placed with a 400 C (sticking) compaction roller gave DCB initiation toughness numbers comparable to those reported for autoclave processed panels but were found to have unexpectedly high void contents. Placement with compaction roller temperatures that prevented roller sticking resulted in mode I fracture toughness approximately 70% that reported for autoclave processed panels. The variability in strength among specimens placed with reduced roller temperature was found to be greatly reduced, which implies that use of supplemental nip point heat may improve the robustness of the tow placement process. Use of the IR heat source permitted placement with a compaction roller temperature that would have resulted in negligible interfacial strength with the hot gas torch alone. The roller temperature reductions eliminated the need for the robot operator to attend placement operations.
An instrument (eroding potentionmeter) has been designed to measure real-time case wall and inhibitor insulation char depth within a rocket motor during firing. Thus measurement can be close to the real-time recession of the insulation surface. The eroding potentionmeter consists of two small (3 mils 9in diameter) twisted resistive wires that are polyimide insulated. The wire pair form an electrical circuit and will recede with the erosion of the rocket motor internal insulation. A constant current applied along the wires will detect the resistance change via a voltage drop across the wires as the wire pair recedes with the decomposition fo the insulation. The eroding potentionmeter, as presently designed, can be an effective tool for real time measurement of internal insulation recession of a solid rocket motor. This tool will provide a way to accurately measure inhibitor performance or to measure flight effects of insulation erosion on a flight test. The eroding potentiometer has been verified on a plasma torch test and two static tests of a small solid rocket motor. There are some irregularities in the measured date, but the data remains useful in determining the real-time performance of internal insulation during a motor firing.
The Space Shuttle Main Engine (SSME) consists of 1080 conical tubes, which are furnace brazed themselves, manifolds, and surrounding structural jacket making almost four miles of braze joints. Subsequent furnace braze cycles are performed due to localized braze voids between the coolant tubes. SSME nozzle experiences extremely high heat flux (180 mW/sq m) during hot fire. Braze voids between coolant tubes may result in hot combustion gas escape causing jacket bulges. The nozzle can be disqualified for flight or result in mission failure if the braze voids exceed the limits. Localized braze processes were considered to eliminate braze voids, however, damage to the parent materials often prohibited use of such process. Being the only manned flight reusable rocket engine, it has stringent requirement on the braze process. Poor braze quality or damage to the parent materials limits the nozzle service life. The objective of this study was to develop a laser brazing process to provide quality, localized braze joints without adverse affect on the parent materials. Gold (Au-Cu-Ni-Pd-Mn) based high temperature braze alloys were used in both powder and wire form. Thin section iron base superalloy A286 tube was used as substrate materials. Different Laser Systems including CO2 (10.6 micrometers, 1kW), ND:YAG (1.06 micrometers, 4kW). and direct diode laser (808nm. 150W) were investigated for brazing process. The laser process variables including wavelength. laser power, travel speed and angle of inclination were optimized according to bead geometry and braze alloy wetting at minimum heat input level, The properties of laser brazing were compared to that of furnace brazing. Microhardness profiles were used for braze joint property comparison between laser and furnace brazing. The cooling rate of laser brazing was compared to furnace brazing based on secondary dendritic arm spacing, Both optical and Scanning Electron Microscope (SEM) were used to evaluate the microstructures of the braze materials and tube substrate. Metallography of the laser braze joint was compared to the furnace braze. SEM Energy Disperse X-Ray Spectra (EDX) and back scattered imaging were used to analyze braze alloy segregation. Although all of the laser systems, CO2, ND:YAG, and direct diode laser produced good braze joint, the direct diode laser was selected for its system simplicity, compactness and portability. Excellent laser and braze alloy coupling is observed with powder alloy compared to braze alloy wire. Good wetting is found with different gold based braze alloys. The laser brazing process can be optimized so that the adverse affect on the parent materials can be eliminated. Metallography of the laser braze joint has shown that quality braze joint was produced with laser brazing process. Penetration of the laser braze to the substrate is at neglectable level. Zero penetration is observed. Microstructure examinations shown that no observable changes of the microstructure (grain structure and precipitation) in the HAZ area between laser braze and furnace braze. Wide gaps can be laser brazed with single pass for up to 0.024 inches. Finer dendritic structure is observed in laser brazing compared with equiaxial and coarser grain of the furnace brazing microstructure. Greater segregation is also found in the furnace braze. Higher hardness of the laser braze joint comparing to furnace braze is observed due to the fast cooling rate and Finer microstructure in the laser brazing. Laser braze joint properties meet or exceed the furnace joint properties. Direct diode laser for thin section tube brazing with high temperature braze alloys have been successfully demonstrated. The laser's high energy density and precise control has shown significant advantages in reducing process heat input to the substrates and provide high quality braze joints comparing to other localized braze process such as torch, TIG, and MPTA processes. Significant cost savings can be realized particularly with localized braze comparing to a full furnace braze cycle.
A non-toxic dual thrust RCS engine offers significant operational, safety, and performance advantages to the space shuttle and the next generation RLVs. In this concept, a single engine produces two thrust levels of 25 and 870 lbf. The low thrust level is provided by the spark torch igniter, which, with the addition of 2 extra valves, can also be made to function as a vernier. A dual thrust RCS engine allows 38 verniers to be packaged more efficiently on a vehicle. These 38 vemiers improve translation and reduce cross coupling, thereby providing more pure roll, pitch, and yaw maneuvers of the vehicle. Compared to the 6 vemiers currently on the shuttle, the 38 dual thrust engines would be 25 to 40% more efficient for the same maneuvers and attitude control. The vernier thrust level also reduces plume impingement and contamination concerns. Redundancy is also improved, thereby improving mission success reliability. Oxygen and ethanol are benign propellants which do not create explosive reaction products or contamination, as compared to hypergolic propellants. These characteristics make dual-thrust engines simpler to implement on a non-toxic reaction control system. Tests at WSTF in August 1999 demonstrated a dual-thrust concept that is successful with oxygen and ethanol. Over a variety of inlet pressures and mixture ratios at 22:1 area ratio, the engine produced between 230 and 297 sec Isp, and thrust levels from 8 lbf. to 50 lbf. This paper describes the benefits of dual-thrust engines and the recent results from tests at WSTF.