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At least 307 records · Page 17

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NASA NTRS1999

Mechanical Property Analysis in the Retracted Pin-Tool (RPT) Region of Friction Stir Welded (FSW) Aluminum Lithium 2195

The "Auto-Adjustable Pin Tool for Friction Stir Welding", was developed at The Marshall Space Flight Center to address process deficiencies unique to the FSW process. The auto-adjustable pin tool, also called the retractable pin-tool (R.PT) automatically withdraws the welding probe of the pin-tool into the pin-tool's shoulder. The primary function of the auto-adjustable pin-tool is to allow for keyhole closeout, necessary for circumferential welding and localized weld repair, and, automated pin-length adjustment for the welding of tapered material thickness. An overview of the RPT hardware is presented. The paper follows with studies conducted using the RPT. The RPT was used to simulate two capabilities; welding tapered material thickness and closing out the keyhole in a circumferential weld. The retracted pin-tool regions in aluminum- lithium 2195 friction stir weldments were studied through mechanical property testing and metallurgical sectioning. Correlation's can be =de between retractable pin-tool programmed parameters, process parameters, microstructure, and resulting weld quality.

Ding, R. Jeffrey↗

NASA NTRS2002

Friction-Stir Welding of Aluminum For the Space Program

The Marshall Space Flight Center is developing and characterizing the friction stir welding process for the Space Shuttle and other space programs. This revolutionary process, invented and patented by The Weld Institute in England, offers tremendous advantages for joining aluminum for high performance applications. It is particularly suited for advanced aluminum-lithium alloys, such as 2195, the primary structural alloy used in the External Tank. The friction stir welding process joins metals with minimal heat input, resulting in high-strength joints with high ductility. It is a simple process to demonstrate using a common milling machine for sample parts, but relatively expensive to implement on large-scale hardware, due to the high cost of tooling needed to handle the high forging pressures characteristic of the process. Recent developments at the Marshall Space Flight Center have demonstrated friction stir welding on linear joints up to 5 meters (15 ft.), with material thickness ranging between 2.5 mm and 16.5 mm (0.100" to 0.650"). High efficiency weld joints have been produced in aluminum from the 2000, 5000, and 6000 series alloy systems. A "retractable pin tool" system was patented by MSFC that allows use of friction stir welding for joints with changing material thickness, and with less rigid tooling than previously considered. This presentation will describe the details of alloys welded to-date and technical advances under development at MSFC. These developments could have substantial benefit to industrial applications for welding aluminum.

Jones, Clyde S.↗

NASA NTRS2003

Thermo-Mechanical Processing in Friction Stir Welds

Friction stir welding is a solid-phase joining, or welding process that was invented in 1991 at The Welding Institute (TWI). The process is potentially capable of joining a wide variety of aluminum alloys that are traditionally difficult to fusion weld. The friction stir welding (FSW) process produces welds by moving a non-consumable rotating pin tool along a seam between work pieces that are firmly clamped to an anvil. At the start of the process, the rotating pin is plunged into the material to a pre-determined load. The required heat is produced by a combination of frictional and deformation heating. The shape of the tool shoulder and supporting anvil promotes a high hydrostatic pressure along the joint line as the tool shears and literally stirs the metal together. To produce a defect free weld, process variables (RPM, transverse speed, and downward force) and tool pin design must be chosen carefully. An accurate model of the material flow during the process is necessary to guide process variable selection. At MSFC a plastic slip line model of the process has been synthesized based on macroscopic images of the resulting weld material. Although this model appears to have captured the main features of the process, material specific interactions are not understood. The objective of the present research was to develop a basic understanding of the evolution of the microstructure to be able to relate it to the deformation process variables of strain, strain rate, and temperature.

Schneider, Judy↗

NASA NTRS2004

Evaluation of Training Samples Manually Welded With the Universal Handtool in a Space Simulation Chamber

The international space welding experiment was designed to evaluate the universal handtool (UHT) functions as a welding, brazing, coating, and cutting tool for in-space operations. The UHT is an electron beam welding system developed by the Paton Welding Institute (PWI), Kiev, Ukraine, and operated a 8 kV with up to 1 kW of power. In preparation for conducting the space welding experiment, cosmonauts were trained to properly operate the UHT and correctly process samples. This Technical Memorandum presents the results of the destructive and nondestructive evaluation of the training samples made in Russia in 1998. It was concluded that acceptable welds can be made with the UHT despite the constraints imposed by a space suit. The lap joint fillet weld configuration was more suitable than the butt joint configuration for operators with limited welding experience. The tube braze joint configuration designed by the PWI was easily brazed in a repeatable manner.

Russell, C. K.↗

NASA NTRS1992

Automated Weld Characterization Using the Thermoelectric Method

The effective assessment of the integrity of welds is a complicated NDE problem that continues to be a challenge. To be able to completely characterize a weld, detailed knowledge of its tensile strength, ductility, hardness, microstructure, macrostructure, and chemical composition is needed. NDE techniques which can provide information on any of these features are extremely important. In this paper, we examine a seldom used approach based on the thermoelectric (TE) effect for characterizing welds and their associated heat affected zone (HAZ). The thermoelectric method monitors the thermoelectric power which is sensitive to small changes in the kinetics of the conduction electrons near the Fermi surface that can be caused by changes in the local microstructure. The technique has been applied to metal sorting, quality testing, flaw detection, thickness gauging of layers, and microscopic structural analysis. To demonstrate the effectiveness of the technique for characterizing welds, a series of tungsten-inert-gas welded Inconel-718 samples were scanned with a computer controlled TE probe. The samples were then analyzed using a scanning electron microscope and Rockwell hardness tests to characterize the weld and the associated HAZ. We then correlated the results with the TE measurements to provide quantitative information on the size of the HAZ and the degree of hardness of the material in the weld region. This provides potentially valuable information on the strength and fatigue life of the weld. We begin the paper by providing a brief review of the TE technique and then highlight some of the factors that can effect the measurements. Next, we provide an overview of the experimental procedure and discuss the results. Finally, we summarize our findings and consider areas for future research.

Fulton, J. P.↗

NASA NTRS1993

Welding arc length control system

The present invention is a welding arc length control system. The system includes, in its broadest aspects, a power source for providing welding current, a power amplification system, a motorized welding torch assembly connected to the power amplification system, a computer, and current pick up means. The computer is connected to the power amplification system for storing and processing arc weld current parameters and non-linear voltage-ampere characteristics. The current pick up means is connected to the power source and to the welding torch assembly for providing weld current data to the computer. Thus, the desired arc length is maintained as the welding current is varied during operation, maintaining consistent weld penetration.

Iceland, William F.↗

NASA NTRS2003

Filler wire for aluminum alloys and method of welding

A weld filler wire chemistry has been developed for fusion welding 2195 aluminum-lithium. The weld filler wire chemistry is an aluminum-copper based alloy containing high additions of titanium and zirconium. The additions of titanium and zirconium reduce the crack susceptibility of aluminum alloy welds while producing good weld mechanical properties. The addition of silver further improves the weld properties of the weld filler wire. The reduced weld crack susceptibility enhances the repair weldability, including when planishing is required.

Bjorkman, Jr., Gerald W. O.↗

NASA NTRS2007

Counterrotating-Shoulder Mechanism for Friction Stir Welding

A counterrotating-shoulder mechanism has been proposed as an alternative to the mechanism and fixtures used in conventional friction stir welding. The mechanism would internally react most or all of the forces and torques exerted on the workpiece, making it unnecessary to react the forces and torques through massive external fixtures. In conventional friction stir welding, a rotating pin tool is inserted into, and moved along, a weld seam. As the pin tool moves, it stirs together material from the opposite sides of the seam to form the weld. A large axial plunge force must be exerted upon the workpiece through and by the pin tool and a shoulder attached above the pin tool in order to maintain the pressure necessary for the process. The workpiece is secured on top of an anvil, which supports the workpiece against the axial plunge force and against the torque exerted by the pin tool and shoulder. The anvil and associated fixtures must be made heavy (and, therefore, are expensive) to keep the workpiece stationary. In addition, workpiece geometries must be limited to those that can be accommodated by the fixtures. The predecessor of the proposed counterrotating-shoulder mechanism is a second-generation, self-reacting tool, resembling a bobbin, that makes it possible to dispense with the heavy anvil. This tool consists essentially of a rotating pin tool with opposing shoulders. Although the opposing shoulders maintain the necessary pressure without need to externally apply or react a large plunge force, the torque exerted on the workpiece remains unreacted in the absence of a substantial external fixture. Depending on the RPM and the thickness of the workpiece, the torque can be large. The proposed mechanism (see figure) would include a spindle attached to a pin tool with a lower shoulder. The spindle would be coupled via splines to the upper one of three bevel gears in a differential drive. The middle bevel gear would be the power-input gear and would be coupled to the upper and lower bevel gears. The lower bevel gear would be attached to the upper shoulder and would slide and rotate freely over the spindle. The spindle would be fastened by its threaded upper end to an external submechanism that would exert axial tension on the spindle to load the workpiece in compression between the shoulders. By reducing or eliminating (relative to the use of a self reacting tool) the torque that must be reacted externally, the use of the proposed tool would reduce the tendency toward distortion or slippage of the workpiece. To begin a weld, the spindle would be inserted through a hole in the workpiece or run-on tab at the beginning of the seam and fastened to the loading submechanism. Rotation and axial loading would be increased gradually from zero and, after a time to be determined by trial and error, translation along the weld seam would be increased gradually from zero to a steady weld speed. The weld would be ended by running the mechanism off the workpiece or, if the lower shoulder were detachable, by detaching the lower shoulder from the spindle and pulling the pin tool out.

Nunes, Arthur C., Jr.↗

NASA NTRS2011

Metallographic Preparation of Space Shuttle Reaction Control System Thruster Electron Beam Welds for Electron Backscatter Diffraction

A Space Shuttle Reaction Control System (RCS) thruster failed during a firing test at the NASA White Sands Test Facility (WSTF), Las Cruces, New Mexico. The firing test was being conducted to investigate a previous electrical malfunction. A number of cracks were found associated with the fuel closure plate/injector assembly (Fig 1). The firing test failure generated a flight constraint to the launch of STS-133. A team comprised of several NASA centers and other research institutes was assembled to investigate and determine the root cause of the failure. The JSC Materials Evaluation Laboratory was asked to compare and characterize the outboard circumferential electron beam (EB) weld between the fuel closure plate (Titanium 6Al-4V) and the injector (Niobium C-103 alloy) of four different RCS thrusters, including the failed RCS thruster. Several metallographic challenges in grinding/polishing, and particularly in etching were encountered because of the differences in hardness, ductility, and chemical resistance between the two alloys and the bimetallic weld. Segments from each thruster were sectioned from the outboard weld. The segments were hot-compression mounted using a conductive, carbon-filled epoxy. A grinding/polishing procedure for titanium alloys was used [1]. This procedure worked well on the titanium; but a thin, disturbed layer was visible on the niobium surface by means of polarized light. Once polished, each sample was micrographed using bright field, differential interference contrast optical microscopy, and scanning electron microscopy (SEM) using a backscatter electron (BSE) detector. No typical weld anomalies were observed in any of the cross sections. However, areas of large atomic contrast were clearly visible in the weld nugget, particularly along fusion line interfaces between the titanium and the niobium. This prompted the need to better understand the chemistry and microstructure of the weld (Fig 2). Energy Dispersive X-Ray Spectroscopy (EDS) was used to confirm the chemical composition of the variations in contrast in these areas. Niobium alloys generally require exposure to more aggressive chemical reagents than titanium alloys for etching because of niobium s chemical resistance; therefore, the titanium portion of the sample was etched first. A five second immersion in Kroll s reagent revealed a general microstructure on the titanium portion of the sample; however, the titanium heat affected zone closest to the weld, was over-etched due to higher concentrations of refined grains and an increase in eta-phase. The Kroll s etchant also revealed some microstructure in the weld nugget itself; the niobium portion of the sample remained unetched.

Martinez, James↗

NASA NTRS2011

Friction Pull Plug Welding in Aluminum Alloys

NASA fs Marshall Space Flight Center (MSFC) has recently invested much time and effort into the process development of Friction Pull Plug Welding (FPPW). FPPW, is a welding process similar to Friction Push Plug Welding in that, there is a small rotating part (plug) being spun and simultaneously pulled (forged) into a larger part. These two processes differ, in that push plug welding requires an internal reaction support, while pull plug welding reacts to the load externally. FPPW was originally conceived as a post proof repair technique for External Tank. FPPW was easily selected as the primary process used to close out the termination hole on the Constellation Program fs ARES I Upper Stage circumferential Self ] Reacting Friction Stir Welds (SR ]FSW). The versatility of FPPW allows it to also be used as a repair technique for both SR ]FSW and Conventional Friction Stir Welds. To date, all MSFC led development has been concentrated on aluminum alloys (2195, 2219, and 2014). Much work has been done to fully understand and characterize the process fs limitations. A heavy emphasis has been spent on plug design, to match the various weldland thicknesses and alloy combinations. This presentation will summarize these development efforts including weld parameter development, process control, parameter sensitivity studies, plug repair techniques, material properties including tensile, fracture and failure analysis.

Brooke, Shane A.↗

DOE OSTI2019

Neutron Residual Stress Mapping of Repaired Spent Nuclear Fuel Welded Stainless-Steel Canisters

Stress corrosion cracking (SCC) caused by atmospheric deposition and deliquescence of aggressive compounds such as chloride-containing salts or oxidized sulfur species may pose a potential issue to the extended service life of spent nuclear fuel (SNF) storage canisters. When a chemically susceptible material is exposed to a hostile environment (e.g., coastal salt air) for a sufficient length of time, SCC may occur at locations on the canister which have undergone high tensile residual stress. These locations are often found in weld zones and the heat-affected zones (HAZ) of welded joints. Ideally, these cracks could be repaired by traditional fusion welding techniques, but the highly localized heat input of the repair welding may introduce additional high tensile residual stress and could increase the risk for future SCCs. This paper presents the results of neutron residual stress mapping of as-welded and repaired stainless steel specimens. The as-welded specimens were provided by Sandia National Laboratories from a canister mock-up manufactured using procedures similar to those used for actual canister production. ASME-qualified gas-tungsten arc welding (GTAW) was used to repair the specimens, and post-repair residual stresses were measured using neutron diffraction at the Oak Ridge National Laboratory (ORNL) High Flux Isotope Reactor (HFIR). As-welded and repaired specimen residual stress distributions are evaluated and compared.

Chatzidakis, Stylianos↗

DOE OSTI2020

Progressive collapse analysis of stiffened panel structure with consideration of actual welding distortion and residual stresses

To date, inclusion of welding distortion and residual stresses in determining the strength of marine structures is based on empirical formulations due to welding complexity. In this study, a more feasible numerical model was developed from the perspective of inherent strain theory. The accuracy of this simplified numerical model was confirmed by transient thermo-elastic–plastic finite element analysis using a novel dynamic mesh refining and iterative substructure method which is 50 times faster than conventional finite element method. Welding distortion by the two numerical approaches was validated with experimental measurement. The collapse analyses indicated that the inherent strain model predicted a compressive strength and load-displacement curve with high accuracy, as validated by the transient thermo-mechanical model. The global stiffness and the ultimate strength of the welded structure would be overestimated by about 22% if no welding effects were considered. The proposed computation procedure for determining the ultimate strength of welded structures is accurate, simple, and practical and enables improvement of ultimate strength through optimization of welding joint design to reduce the welding residual stress and distortion.

Huang, Hui↗

DOE OSTI2018

Impact of initial temper of base metal on microstructure and mechanical properties of friction stir welded AA 7055 alloy

Highlights: • Friction stir welded 7055-T4 alloy exhibits higher tensile properties than T6 alloy. • Friction stir welded 7055-T4 alloy exhibits more uniform hardness distribution. • Some regions in heat affected zone have higher hardness than base metal in T4-joint. • Effect of initial temper on precipitate evolution in different zones is discussed. AA 7055-T6 and AA 7055-T4 aluminium alloy sheets were friction stir welded to investigate the impact of initial base metal temper on microstructure, hardness and tensile properties of the joints. In the joint of alloy in T6 temper (T6-joint), the hardness of the weld zone is lower than that of base metal; in the joint of alloy in T4 temper (T4-joint), however, some regions in the heat affected zone exhibit higher hardness than base metal. The weld nugget zone in T6-joint exhibits slightly lower hardness compared with that in T4-joint. The hardness minima is slightly higher in T4-joint than in T6-joint. T4-joint exhibits higher yield strength, ultimate tensile strength and elongation compared with T6-joint. Based on microstructure examination by transmission electron microscopy, the impact of initial precipitate state on precipitation behavior in the weld nugget zone, thermo-mechanically affected zone and heat affected zone during friction stir welding and mechanical properties of the joints is discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Non-circular electron beam spot welds in stainless steel alloys

Circularly symmetric-shaped spot welds are desirable for welding applications as they relate to heat and fluid flow conditions in the melt pool with predictable weld penetrations and repeatable results. Non-circular spot welds on the other hand result in undesirable and unpredictable weld penetrations or non-bridging of the liquid melt pool across the joint. Two known causes for non-circular melt pools occur when welding dissimilar metals, or when welding with skewed electron or laser beams that are not perpendicular to the surface. A largely unexplored additional factor, shown here, is an asymmetric power density distribution within the beam that can create non-circular melt pools even though the beam dimensions are much smaller than the melt pool itself.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Enhancing NDE Reliability for Grade 91 Steel Welds: Ultrasonic Imaging and Microstructural Correlations

Ensuring the integrity of Grade 91 (9Cr-1Mo-V) steel welds is vital for the safe and reliable operation of fossil fuel–fired and nuclear power plants. Here, this study applies an imaging technique for the ultrasonic characterization of two Grade 91 steel welds created with cold metal transfer and flux-cored arc welding processes. Ultrasonic immersion testing in the through-transmission configuration was employed to generate shear waves, which helped identify the weld metal, heat-affected zone, and base metal regions. These weld microstructures were also correlated to their ultrasonic images using metallography, ultrasonic amplitude, hardness measurements, and grain size. The findings from this study can assist practitioners in developing new nondestructive evaluation technologies, improving the inspection reliability of creep strength–enhanced ferritic steel welds by potentially identifying weld microstructure regions susceptible to creep-type failures.

Grade 91 steel↗

NASA NTRSDate not supplied

Maturation of In-space Welding in Reduced Gravity and Reduced Pressure Environments Through Progression to Suborbital Flight Experiments

Development of in-space welding (ISW) is a key and enabling manufacturing technology as welding is currently involved in producing approximately 90% of durable goods, and this trend is expected to hold for in-space manufacturing as well. ISW is critical to a sustainable space economy. To mature in-space welding, numerous gaps must be closed since NASA has not made a weld in space in 50 years. Advancing laser beam welding (LBW) towards a suborbital flight demonstration will help mature the process for in-space assembly & manufacturing (ISAM) through demonstration in relevant environments and achieving technology readiness milestones. LBW technologies and science improved by this work will benefit in-space manufacturing, long-term sustainability of space structures & operations, and the overall space economy. Ground-based welding of aerospace hardware requires an Edisonian approach to qualify a welding process; however, this approach is infeasible for ISW qualification due to mass, volume, logistic, and cost challenges inherent to the space environment. To address this challenge, we are conducting ground and suborbital tests with partners performing parabolic flights to gather data on LBW processes and infuse them into NASA & partner missions. This progression from ground to flight experiments will elucidate relevant physics during LBW: 1) reduced gravity, 2) reduced pressure, and 3) extreme temperature. Data from post-flight evaluation and in situ instrumentation will feed integrated computational materials engineering (ICME) tools to reduce the burden of ISW infusion by establishing a link between space and terrestrial environments, ultimately accelerating the qualification of LBW in space.

in-space welding↗

DOE OSTI2018

Effect of Annealing on the Microstructure and Properties of Electron Beam Welded 4J34 Kovar Alloy

Electron beam welding of 4J34 Kovar alloy was conducted, and the microstructure and mechanical properties of the joints in as-welded and postweld annealing treatment (PWAT) states were investigated. The martensitic transformation occurred and led to the generation of α lath martensite due to the rapid cooling in the as-welded condition. After annealing treatment, part of the α martensite transformed to γ austenite and subsequently developed the bulk γ phase and α/γ lamellar microstructures in the fusion zone (FZ) of the postwelded joint. Grains in the heat-affected zone (HAZ) clearly developed and penetrated into the FZ, causing the disappearance of the fusion line between the FZ and the HAZ. All the joints in both the as-welded and PWAT conditions exhibited ductile fracture. The maximum tensile strength of 505 MPa was obtained in the as-welded joint with the welding speed of 150 mm/min. The linear expansion coefficients of the joint and base metal decreased with the increase in temperature. However, the decreasing rate of PWAT joints was lower than that of the as-welded joints.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Weld Quality Assessment in Fiber Laser Weldments of Ti-6Al-4V Alloy

Laser welding experiments are performed on Ti-6Al-4V alloy sheets by adopting fiber laser. A special kind of workpiece fixture is designed and fabricated for providing shielding gas. After experiments, penetration depth, fusion zone width and heat-affected zone size at different locations within weld bead are measured and discussed in detail. Influence of line energies on the formation of non-uniform microstructure within weld bead is explored by conducting microstructural analysis. Various kinds of microstructural morphology of martensitic structure such as α′ martensite, blocky α, massive α and basket-weave microstructure are found in fusion zone. Experimentally, it is found that beam power is the key parameter for controlling penetration depth. Higher hardness is noticed within fusion zone due to the existence of large volume of α′ martensite. Tensile strength and hardness of welded specimens are increased with decreasing line energy. Small amount of micropores are also found in solidified weld bead. However, its sizes are in acceptable range as per BSEN:4678 standard. Most favorable welding condition is identified as a combination of beam power of 800 W and welding speed of 1000 mm/min which yields full penetration, narrower bead width, small heat-affected zone, minimal defects and acceptable mechanical properties.

36 MATERIALS SCIENCE↗