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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

Microstructure Characterization and Stress Corrosion Evaluation of Autogenous and Hybrid Friction Stir Welded Al-Cu-Li 2195 Alloy

Friction stir welding process is being evaluated for application on the Al-Cu-Li 2195 Super-Light Weight External Tank of the Space Transportation System. In the present investigation Al-Cu-Li 2195 plates were joined by autogenous friction stir welding (FSW) and hybrid FSW (friction stir welding over existing variable polarity plasma arc weld). Optical microscopy and transmission electron microscopy (TEM) were utilized to characterize microstructures of the weldments processed by both welding methods. TEM observations of autogenous FSW coupons in the center section of the dynamically-recrystallized zone showed an equiaxed recrystallized microstructure with an average grain size of approx. 3.8 microns. No T(sub 1), precipitates were present in the above-mentioned zone. Instead, T(sub B) and alpha precipitates were found in this zone with a lower population. Alternate immersion, anodic polarization, constant load, and slow strain tests were carried out to evaluate the general corrosion and stress-corrosion properties of autogenous and hybrid FSW prepared coupons. The experimental results will be discussed.

Li, Zhixian↗
NASA NTRS1999

Nondestructive Evaluation of the Friction Weld Process on 2195/2219 Grade Aluminum

In 1996, NASA's Marshall Space Flight Center began an ambitious program designed to find alternative methods of repairing conventional TIG (Tungsten Inert Gas) welds and VPPA (Variable Polarity Plasma Arc) welds on the Space Shuttle External Tank without producing additional heat-related anomalies or conditions. Therefore, a relatively new method, invented by The Welding Institute (TWI) in Cambridge, England, called Friction Stir Welding (FSW), was investigated for use in this application, as well as being used potentially as an initial weld process. As with the conventional repair welding processes, nondestructive evaluation (NDE) plays a crucial role in the verification of these repairs. Since it was feared that conventional NDE might have trouble with this type of weld structure (due to shape of nugget, grain structure, etc.) it was imperative that a complete study be performed to address the adequacy of the NDE process. This paper summarizes that process.

Suits, Michael W.↗
NASA NTRS1999

Stability of Full Penetration, Flat Position Weld Pools

The dynamics of the dropthrough distance of a full penetration, flat position weld pool is described. Close to incipient root side penetration the dropthrough is metastable, so that a small drop in power can cause a loss of penetration if not followed soon enough by a compensating rise in power. The SPA (Soft Plasma Arc) process with higher pressure on top of the weld pool loses penetration more quickly than the GTA (Gas Tungsten Arc) process. 2195 aluminum-lithium alloy with a lower surface tension loses penetration more quickly than 2219 aluminum alloy. An instance of loss of penetration of a SPA weld in 2195 aluminum-lithium alloy is discussed in the light of the model.

Nunes, Arthur C., Jr.↗
NASA NTRS1996

Advanced Welding Torch

In order to more easily join the huge sections of the Space Shuttle external tank, Marshall Space Flight Center initiated development of the existing concept of Variable Polarity Plasma Arc (VPPA) welding. VPPA welding employs a variable current waveform that allows the system to operate for preset time increments in either of two polarity modes for effective joining of light alloys. Marshall awarded the torch contract to B & B Precision Machine, which produced a torch for the Shuttle, then automated the system, and eventually delivered a small torch used by companies such as Whirlpool for sheet metal welding of appliance parts and other applications. The dependability of the torch offers cost and time advantages.

Source record↗
NASA NTRS2002

Alternative Processing Methods for Ultra High Temperature Ceramics

Ultra High Temperature Ceramics (UHTCs) are being developed for possible use in a number of structural applications including hypersonic vehicles, engines, plasma arc electrodes and high temperature shielding. Alternative methods of processing Ultra High Temperature Ceramics (UHTCs) will be discussed. Techniques that may improve oxidation resistance, strength, and reduce the processing temperature of the UHTCs will be presented. Hot-pressed UHTCs made using either milled/uncoated powders or non-milled coated powders will be compared.

Gusman, Michael↗
NASA NTRS2005

Diode Laser Sensors for Arc-Jet Characterization

The development and application of tunable diode laser (TDL) absorption sensors to monitor the health and operating conditions in the large-scale 60 MW arc-heated- plasma wind-tunnel at NASA Ames Research Center is reported. The interactive heating facility (THF) produces re-entry flow conditions by expanding the gas heated in a constricted plasma arc-heater to flow at high velocity over a model located in a test cabin. This facility provides the conditions needed to test thermal protective systems for spacecraft re-entering the earth s atmosphere. TDL sensors are developed to monitor gas flows in both the high-temperature constricted flow and the supersonic expansion flow into test cabin. These sensors utilize wavelength-tuned diode lasers to measure absorption transitions of atomic oxygen near 777.2 nm, atomic nitrogen near 856.8 nm, and atomic copper near 793.3 nm. The oxygen and nitrogen sensors measure the population density in exited electronic states of these atoms. The measurements combined with the assumption of local thermal and chemical equilibrium yield gas temperature (typically near 7,000K). The nitrogen and oxygen population temperatures are redundant, and their close agreement provides an important test of the local thermal equilibrium assumption. These temperature sensors provide time-resolved monitors of the operating conditions of the arc-heater and can be used to verify and control the test conditions. An additional TDL sensor was developed to monitor the copper concentration in the arc-heater flow yielding values as high as 13 ppm. Measurements of copper in the flow can identify flow conditions with unacceptably rapid electrode erosion, and hence this sensor provides valuable information needed to schedule maintenance to avoid costly arc-heater failure. TDL sensors were also developed for measurements in the test cabin, where absorption measurements of the populations of argon and molecular nitrogen in excited metastable electronic states established that the number density of these excited species is much lower than estimated using frozen-chemistry approximations. This key finding suggests that in the post-expansion region there is not a significant energy sequestration in electronically excited species. Finally, TDL measurements of atomic potassium seeded into the test cabin flow were used to directly measure the static temperature of the test gas. The results of this study illustrate the high potential of time-resolved TDL measurements for routine and economical sensing of arc-heater health (gas temperature and electrode erosion) as well as the time-resolved test-cabin-flow conditions in front of the model.

Hanson, Ronald K.↗
NASA NTRS2006

A Decade of Friction Stir Welding R and D at NASA's Marshall Space Flight Center and a Glance into the Future

Welding at NASA's Marshall Space Flight Center (MSFC), Huntsville, Alabama, has taken a new direction through the last 10 years. Fusion welding processes, namely variable polarity plasma arc (VPPA) and tungsten inert gas (TIG) were once the corner stone of welding development in the Space Flight Center's welding laboratories, located in the part of MSFC know as National Center for Advanced Manufacturing (NCM). Developed specifically to support the Shuttle Program's External Tank and later International Space Station manufacturing programs, was viewed as the paragon of welding processes for joining aluminum alloys. Much has changed since 1994, however, when NASA's Jeff Ding brought the FSW process to the NASA agency. Although, at that time, FSW was little more than a "lab curiosity", NASA researchers started investigating where the FSW process would best fit NASA manufacturing programs. A laboratory FSW system was procured and the first welds were made in fall of 1995. The small initial investment NASA made into the first FSW system has certainly paid off for the NASA agency in terms of cost savings, hardware quality and notoriety. FSW is now a part of Shuttle External Tank (ET) production and the preferred weld process for the manufacturing of components for the new Crew Launch Vehicle (CLV) and Heavy Lift Launch Vehicle (HLLV) that will take this country back to the moon. It is one of the solid state welding processes being considered for on-orbit space welding and repair, and is of considerable interest for Department of Defense @OD) manufacturing programs. MSFC involvement in these and other programs makes NASA a driving force in this country's development of FSW and other solid state welding technologies. Now, a decade later, almost the entire on-going welding R&D at MSFC now focuses on FSW and other more advanced solid state welding processes.

Ding, Jeff↗
NASA NTRS2008

Thermal Stir Welding Development at Marshall Space Flight Center

Solid state welding processes have become the focus of welding process development at NASA's Marshall Space Flight Center. Unlike fusion weld processes such as tungsten inert gas (TIG), variable polarity plasma arc (VPPA), electron beam (EB), etc., solid state welding processes do not melt the material during welding. The resultant microstructure can be characterized as a dynamically recrystallized morphology much different than the casted, dentritic structure typical of fusion weld processes. The primary benefits of solid state processes over fusion weld processes include superior mechanic properties and the elimination of thermal distortion and residual stresses. These solid state processes attributes have profoundly influenced the direction of advanced welding research and development within the NASA agency. Thermal Stir Welding (TSW) is a new solid state welding process being developed at the Marshall Space Flight Center. Unlike friction stir welding, the heating, stirring and forging elements of the weld process can be decoupled for independent control. An induction coil induces energy into a workpiece to attain a desired plastic temperature. An independently controlled stir rod, captured within non-rotating containment plates, then stirs the plasticized material followed by forging plates/rollers that work the stirred weld joint. The independent control (decoupling) of heating, stirring and forging allows, theoretically, for the precision control of microstructure morphology. The TSW process is being used to evaluate the solid state joining of Haynes 230 for ARES J-2X applications. It is also being developed for 500-in (12.5 mm) thick commercially pure grade 2 titanium for navy applications. Other interests include Inconel 718 and stainless steel. This presentation will provide metallurgical and mechanical property data for these high melting temperature alloys.

Ding, Robert J.↗
NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗
NASA NTRS2010

Advanced Welding Applications

Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

Ding, Robert J.↗
NASA NTRS2012

Regolith-Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication

In this paper we will discuss a new mass-efficient and innovative way of protecting high-mass spacecraft during planetary Entry, Descent & Landing (EDL). Heat shields fabricated in situ can provide a thermal-protection system (TPS) for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from regolith materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Two regolith processing and manufacturing methods will be discussed: 1) Compression and sintering of the regolith to yield low density materials; 2) Formulations of a High-temperature silicone RTV (Room Temperature Vulcanizing) compound are used to bind regolith particles together. The overall positive results of torch flame impingement tests and plasma arc jet testing on the resulting samples will also be discussed.

Hogue, Michael D.↗
NASA NTRS1972

Pressure and current effects on the thermal efficiency of an MPD arc used as a plasma source

Measurements of arc voltage and energy loss to the cooled electrodes of a magnetoplasmadynamic (MPD) arc, operating without an applied magnetic field, were made at chamber pressures of 26 to 950 torr, argon mass flow rates of 0.08 to 44 g/s and current of 200 to 2000 A. The resulting arc thermal efficiency varied from 22% at a chamber pressure of 26 torr to 88% at 950 torr. Thermal efficiency was only weakly dependent on arc current. It is concluded that the MPD arc operating without an applied magnetic field and at higher pressure than normally used in thruster applications is a reliable and efficient steady-state plasma source.

Pivirotto, T. J.↗
NASA NTRS2001

Optical Plasma Control During ARC Carbon Nanotube Growth

To improve nanotube production, we developed a novel optical control technique, based on the shape of the visible plasma zone created between the anode and the cathode in the direct current (DC) arc process. For a given inert gas, we adjust the anode to cathode distance (ACD) in order to obtain strong visible vortices around the cathode. This enhance anode vaporization, which improve nanotubes formation. In light of our experimental results, we focus our discussion on the relationship between plasma parameters and nanotube growth. Plasma temperature control during arc process is achieved using argon, helium, and their mixtures as a buffer gases. The variation of the gas mixture from pure argon to pure helium changes plasma temperature. As a consequence, the microscopic characteristics of nanotubes as diameter distribution is changed moving from smaller values for argon to higher diameters for helium. We also observe a dependence of the macroscopic characteristics of the final products as Brunauer-Emmett-Teller (BET) surface area.

Hinkov, I.↗
NASA NTRS1978

Comparative characteristics of electron energy spectrum in PIG and arc type discharge plasmas

The electron distribution functions relative to the velocity component directed along the magnetic field are compared for PIG and arc type discharges. The identity of these functions for the plasma region pierced by the primary electron beam and their difference in the peripheral part of the discharge are shown. It is concluded that the electron distribution function in the PIG type discharge is formed during one transit of the primary electron through the discharge gap. The mechanisms of electron energy spectrum formation in both the axis region and the peripheral region of the discharge are discussed.

Romanyuk, L. I.↗