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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Influence of Heat Input and Cold Wire Feeding Rate on Pitting Corrosion Resistance of Submerged Arc Welding Duplex Stainless Steel Welds

Welding thermal cycles may severely impair duplex stainless steel (DSS) performance, especially local pitting resistance and toughness. The restricted welding energy between 0.5 and 2.5 kJ mm{sup −1} represents a limiting factor for productivity increase in DSS welding, and the addition of cold wire is an interesting alternative to increase the welding deposition rate without adding extra heat. The aim of this work is to evaluate the influence of the cold wire feeding rate (CW) and heat input (HI) on pitting corrosion behavior of DSS UNS S32304 bead-on-plate welds obtained by submerged arc welding (SAW). Cyclic potentiodynamic polarization was carried out in transverse weld sections using 1 mol L{sup −1} NaCl solution at room temperature. Most pitting corrosion spots were located on the heat-affected zone (HAZ), and the pitting potentials were lower than the base metal due to higher ferrite fractions and the presence of chromium nitrides. Considering the same CW, the HI increasing reduced E{sub pit} for 1.6, 1.9, 2.2 kJ mm{sup −1}, but increased E{sub pit} for 2.7 kJ mm{sup −1}, due to a balance between the HAZ width and the austenite fraction.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Quarterly Management Document – FY22, 1st Quarter, Multi-pass Hybrid Laser Arc Welding of Alloy 740H

This report summarizes the progress made on the project during the first quarter of FY22. The model for deep penetration laser welding continues to be developed to understand and mitigate cracking issues associated with laser welding Alloy 740H. The effects of laser wobble on laser welding of this alloy are also being developed. Additionally, the short-term creep behavior of welds made by various hybrid laser arc parameters has been obtained and the results indicate they are comparable to welds made by conventional gas tungsten arc welding which is a factor 2 slower than the hybrid welds. Additionally, the creep behavior of laser-only welds is also consistent with conventional gas tungsten arc welds as well as the hybrid laser arc welds made under this project. However, the creep rate of the laser-only welds is much higher than that observed in the hybrid laser arc welded specimens. This is most likely due to the narrower weld produced by laser-only welding compared to hybrid laser arc welding and, thus, the higher creep rate of laser-only welded creep specimens is likely a result of the increased fraction of base metal (which exhibits a higher creep rate than weld metal) contained within the gage section of the creep specimen. Creep rupture lifetimes were all about the same for both laser-only and hybrid laser arc welded specimens and consistent with the creep rupture lifetime of conventional gas tungsten arc welded creep specimens.

36 MATERIALS SCIENCE↗
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 NTRS1990

Internal Filler-Wire Feed For Arc Welding

Tungsten electrode for gas/tungsten arc welding contains lengthwise channel for feeding filler wire to weld joint. Channel makes it unnecessary to feed wire through guides outside electrode, conserving valuable space near weld and protects wire from deformation by contact with other parts in vicinity of weld. Helpful in robotic or automatic welding.

Morgan, Gene E.↗
NASA NTRS2018

Effects of Mars Atmosphere on Arc Welds: Phase 2

Gas tungsten arc welding (GTAW) is a vital fusion welding process widely used throughout the aerospace industry. Its use may be critical for the repair or manufacture of systems, rockets, or facilities on the Martian surface. Aluminum alloy AA2219-T87 and titanium alloy Ti-6Al-4V butt welds have been investigated for weldability and weld properties in a simulated Martian gas environment. The resulting simulated Martian welds were compared to welds made in a terrestrial atmosphere, all of which used argon shielding gas. It was found that GTAW is a process that may be used in a Martian gas environment, not accounting for pressure and gravitational effects, as long as adequate argon shielding gas is used to protect the weld metal. Simulated Martian welds exhibited higher hardness in all cases and higher tensile strength in the case of AA2219-T87. This has been attributed to the absorption of carbon into the fusion zone, causing carbide precipitates to form. These precipitates may act to pin dislocations upon tensile testing of AA2219-T87. Dissolved carbon may have also led to carburization, which may have caused the increase in hardness within the fusion zone of the welds. Based on the results of this experiment and other similar experiments, GTAW appears to be a promising process for welding in a Martian gas environment. Additional funding and experimentation is necessary to determine the effects of the low pressure and low gravity environment found on Mars on GTAW.

Courtright, Z. S.↗
NASA NTRS1994

Gas arc constriction for plasma arc welding

A welding torch for plasma arc welding apparatus has an inert gas applied circumferentially about the arc column externally of the constricting nozzle so as to apply a constricting force on the arc after it has exited the nozzle orifice and downstream of the auxiliary shielding gas. The constricting inert gas is supplied to a plenum chamber about the body of the torch and exits through a series of circumferentially disposed orifices in an annular wall forming a closure at the forward end of the constricting gas plenum chamber. The constricting force of the circumferential gas flow about the arc concentrates and focuses the arc column into a more narrow and dense column of energy after exiting the nozzle orifice so that the arc better retains its energy density prior to contacting the workpiece.

McGee, William F.↗
DOE OSTI2018

Microstructure and Mechanical Properties of Al-Mg-Sc-Zr Alloy Variable Polarity Plasma Arc Welding Joint

Al-Mg-Sc-Zr alloy plates were welded by variable polarity plasma arc welding (VPPAW) with Sc-containing filler wire. The microstructure and mechanical properties were investigated. Results show that the weld zone and heat-affected zone (HAZ) are narrow due to the high concentrated heat input of VPPAW. Primary Al{sub 3}(Sc,Zr) particles are nice nucleating sites for α-Al, which can significantly refine the grains of α-Al, helping the weld zone maintain an outstanding strength. The unmelted Al{sub 3}(Sc,Zr) precipitates of the base metal aggregated near the fusion boundary result in the formation of a fine equiaxed grains zone, which improves the bonding degree between the weld zone and the base metal. The Al{sub 3}(Sc,Zr) precipitates in the HAZ have excellent inhibition effect on recrystallization. According to the observed microhardness distribution and microstructure characteristics, the microstructure model of welded joint is obtained. The fractured position of welded joint locates in the weld zone. The tensile strength of the welded joint without reinforcing rib is 330 MPa. The welding coefficient reaches 74%.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multi-Pass Hybrid Laser Arc Welding of Alloy 740H

The presentation reviews the progress made toward reducing the joining time of an advanced nickel-based alloy, Alloy 740H by a factor of two using a novel two step fusion welding approach. In the first step, a high powered laser is used to rapidly join thick weld groove lands (~10-12 mm thick) during a single pass. Hybrid laser arc welding (HLAW) is then used to fill the remaining weld groove and complete the joint. This sequential process also utilizes laser wobble in both steps to reduce welding defects and refine the weld microstructure to obtain improved properties compared to conventional gas tungsten or gas metal arc welds, GTAW and GMAW, respectively. The creep behavior of laser-only thick weld groove land welds and HLAW welds were found to be the same or slightly improved compared to conventional GMAW or GTAW welds in this alloy. Creep tests have been started to verify the long-term creep behavior (~10,000 hrs) of these welds. Modeling results on deep penetration laser welding are presented and the initial simulations of laser welding with laser wobble are shown. The next phase of the project will combine the two processes to make complete welds - deep penetration laser welds of thick weld groove lands followed by rapid filling of the remaining weld groove by HLAW - in thick plates (32 mm thick) Alloy 740H plate and entails development of narrow weld groove welding to further decrease the joining time of this alloy.

36 MATERIALS SCIENCE↗
NASA NTRS1994

Plasma arc welding weld imaging

A welding torch for plasma arc welding apparatus has a transparent shield cup disposed about the constricting nozzle, the cup including a small outwardly extending polished lip. A guide tube extends externally of the torch and has a free end adjacent to the lip. First and second optical fiber bundle assemblies are supported within the guide tube. Light from a strobe light is transmitted along one of the assemblies to the free end and through the lip onto the weld site. A lens is positioned in the guide tube adjacent to the second assembly and focuses images of the weld site onto the end of the fiber bundle of the second assembly and these images are transmitted along the second assembly to a video camera so that the weld site may be viewed continuously for monitoring the welding process.

Rybicki, Daniel J.↗
NASA NTRS1968

Closed circuit TV system automatically guides welding arc

Closed circuit television /CCTV/ system automatically guides a welding torch to position the welding arc accurately along weld seams. Digital counting and logic techniques incorporated in the control circuitry, ensure performance reliability.

Stephans, D. L.↗
NASA NTRS1994

Sensing the gas metal arc welding process

Control of gas metal arc welding (GMAW) requires real-time sensing of the process. Three sensing techniques for GMAW are being developed at the Idaho National Engineering Laboratory (INEL). These are (1) noncontacting ultrasonic sensing using a laser/EMAT (electromagnetic acoustic transducer) to detect defects in the solidified weld on a pass-by-pass basis, (2) integrated optical sensing using a CCD camera and a laser stripe to obtain cooling rate and weld bead geometry information, and (3) monitoring fluctuations in digitized welding voltage data to detect the mode of metal droplet transfer and assure that the desired mass input is achieved.

Carlson, N. M.↗
DOE OSTI2021

Quarterly Management Document – FY21, 4th Quarter, Multi-pass Hybrid Laser Arc Welding of Alloy 740H

This report summarizes the progress made on reducing the joining time for thick plates of Alloy 740H. Modeling of deep penetration laser welding of Alloy 740H continues with the goal of explaining cracking in the weld that is observed in experimental laser welds in this alloy. Experimental work was also performed to understand factors influencing hybrid laser arc weld quality as a function of the arc and laser parameters. Laser welds and hybrid laser arc welds have been made using best practices up this point in the project. Welded materials have been sent to a commercial vendor to make creep specimens and perform short term creep tests to help evaluate the quality of the welds that have been made so far.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Ni content on the microstructure and mechanical properties of weld metal with both-side submerged arc welding technique

Highlights: • This manuscript primarily studied the effects of Ni content on the K65 weld metals; • Increase Ni content could significantly improve the strength and low temperature impact toughness of the weld metal. • The beneficial effect of Ni is attributed to its positive effect on phase transformation. • GBF keeps K-S or N-W relations only with one austenite and the variants belong to the same bain group are two reasons. • The M/A islands are considered to be another reason for the reduced toughness. - Abstract: The effects of nickel (Ni) content on the mechanical properties and microstructure evolution in the weld metals of commercial K65 oil and gas pipeline steel were studied. Increase Ni content could significantly improve the strength and low temperature impact toughness (−40 °C and −60 °C) of the weld metal. The above influences of Ni were attributed to the formation of predominant acicular ferrite (AF), at the expense of grain boundary ferrite (GBF), ferrite side plates (FSP) and martensite/austenite (M/A) constituent in weld metal. EBSD results indicated that GBF keeps K-S or N-W relations only with the prior austensite grain that belongs to one side of the grain boundary and the variants belong to the same bain group which always forms low angle boundary. Moreover, the retained austenite as one part of M/A constituent was mainly found in the weld metal with lower Ni content. It indicated that the transformation process could be promoted more completely by the increase of Ni content. The mechanism of the toughness improvement brought by Ni increasing was ascribed to the relatively uniform transformation to final microstructure, which reduces the appearance of GBF and M/A constituents.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental Study of Residual Stresses in Hybrid Laser Arc and Submerged Arc-Welded 10-mm-Thick Low-Carbon Steel Plates

Offshore structures are constantly exposed to a multihazard marine environment that threatens their structural integrity. This imposes a high risk for extensive structural failures while various deterioration mechanisms may degrade the available capacity of the structures. Thus, no reliable decisions can be reached regarding design, operation, and survivability of the structures unless a deep comprehension of their fatigue performance is available, including welding-induced residual stresses. In particular, the continuous increase in size of the weldments for the offshore wind industry needs special attention with regard to welding-induced residual stresses, as they can reduce fatigue life, promote distortion, and contribute to stress corrosion cracking. Thus, the current design methods and increased structural dimensions as well as new design and manufacturing methods need to be inspected, understood, and optimized. Related to this, there is a growing need for evaluation of the effect of welding methods with various heat input density distributions. This article deals with the influence of welding method on the welding-induced residual stresses in 10-mm-thick low-carbon structural steel plates. The residual stresses are investigated in hybrid laser-arc welded and submerged arc butt-welded steel plates by means of experimental temperature profile measurements and neutron diffraction measurements and in accordance with existing production procedures. The residual stresses were measured at three different depths in the plates. The goal of the analysis is to gain a comprehensive understanding of the distribution and development of residual stresses in relation to the welding method for better control of the residual stresses and distortion. Furthermore, the repeatability of the neutron diffraction measurements is also investigated and reported in this article.

36 MATERIALS SCIENCE↗
NASA NTRS1987

Gas tungsten arc welding in a microgravity environment: Work done on GAS payload G-169

GAS payload G-169 is discussed. G-169 contains a computer-controlled Gas Tungsten Arc Welder. The equipment design, problem analysis, and problem solutions are presented. Analysis of data gathered from other microgravity arc welding and terrestrial Gas Tungsten Arc Welding (GTAW) experiments are discussed in relation to the predicted results for the GTAW to be performed in microgravity with payload G-169.

Welcher, Blake A.↗
NASA NTRS1999

Melting Efficiency During Plasma Arc Welding

A series of partial penetration Variable Polarity Plasma Arc welds were made at equal power but various combinations of current and voltage on 2219 aluminum. Arc Efficiency was measured calorimetrically and ranged between 48% and 66%. Melting efficiency depends on the weld pool shape. Increased current increases the melting efficiency as it increases the depth to width ratio of the weld pool. Higher currents are thought to raise arc pressure and depress the liquid at the bottom of the weld pool causing a more nearly two dimensional heat flow condition.

McClure, J.C.↗
NASA NTRS1988

Preventing Arc Welding From Damaging Electronics

Shielding technique developed to protect sensitive electronic equipment from damage due to electromagnetic disturbances produced by arc welding. Established acceptable alternative in instances in which electronic equipment cannot be removed prior to arc welding. Guidelines established for open, unshielded welds. Procedure applicable to robotics or computer-aided manufacturing.

Sargent, Noel↗