Search NASA⌕ Search

SEARCH · Search NASA

Results for “WELDING, RESISTENCE”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

The application of statistically designed experiments to resistance spot welding

State-of-the-art Resistance Spot Welding (RSW) equipment has the potential to permit realtime monitoring of operations through advances in computerized process control. In order to realize adaptive feedback capabilities, it is necessary to establish correlations among process variables, welder outputs, and weldment properties. The initial step toward achieving this goal must involve assessment of the effect of specific process inputs and the interactions among these variables on spot weld characteristics. This investigation evaluated these effects through the application of a statistically designed experiment to the RSW process. A half-factorial, Taguchi L sub 16 design was used to understand and refine a RSW schedule developed for welding dissimilar aluminum-lithium alloys of different thickness. The baseline schedule had been established previously by traditional trial and error methods based on engineering judgment and one-factor-at-a-time studies. A hierarchy of inputs with respect to each other was established, and the significance of these inputs with respect to experimental noise was determined. Useful insight was gained into the effect of interactions among process variables, particularly with respect to weldment defects. The effects of equipment related changes associated with disassembly and recalibration were also identified. In spite of an apparent decrease in equipment performance, a significant improvement in the maximum strength for defect-free welds compared to the baseline schedule was achieved.

Hafley, Robert A.↗
NASA NTRS2015

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗
NASA NTRS1973

Resistance spot welding of dispersion-strengthened nickel alloys

To develop easily-applied production method for resistance spot welding use unrecrystallized sheet material, develop welding schedule that will produce a solid-state spot weld without recrystallizing sheet, and postheat to produce grain growth across weld line during recrystallization of sheet material.

Moore, T. J.↗
NASA NTRS1983

Electronic Force Gage for Welders

Welding force monitored in process. Electronic force gage uses strain gage on deformable member. Oscilloscope trace of welding force photographed and compared with standard trace during calibration and troubleshooting of resistance welding equipment. Adaptable to small scale resistance welding in electronics industry.

Bradley, J. W.↗
NASA NTRS1982

Evaluation of electrode shape and nondestructive evaluation method for welded solar cell interconnects

Resistance welds of solar cell interconnect tabs were evaluated. Both copper-silver and silver-silver welds were made with various heat inputs and weld durations. Parallel gap and annular gap weld electrode designs were used. The welds were analyzed by light microscope, electron microprobe and scanning laser acoustic microscope. These analyses showed the size and shape of the weld, the relationship between the acoustic micrographs, the visible electrode footprint, and the effect of electrode misalignment. The effect of weld heat input on weld microstructure was also shown.

Baraona, C. R.↗
NASA NTRS1982

Microstructural analysis of solar cell welds

Parallel-gap resistance welding of silicon solar cells with copper interconnects results in complex microstructural variations that depend on the welding variables. At relatively low heat input solid-state welds are produced. At medium heat the Ag-Cu eutectic forms resulting in a braze joint. High heat produces a fusion weld with complete melting of the silver layer on the silicon solar cell. If the silicon is also melted, cracking occurs in the silicon cell below the weld nugget. These determinations were made using light microscopy, microprobe, and scanning electron microscopy analyses.

Moore, T. J.↗
NASA NTRS1989

Lightweight, High-Current Welding Gun

Lighweight resistance-welding, hand-held gun supplies alternating or direct current over range of 600 to 4,000 A and applies forces from 40 to 60 lb during welding. Used to weld metal sheets in multilayered stacks.

Starck, Thomas F.↗
NASA NTRS1990

Attachment of lead wires to thin film thermocouples mounted on high temperature materials using the parallel gap welding process

Parallel gap resistance welding was used to attach lead wires to sputtered thin film sensors. Ranges of optimum welding parameters to produce an acceptable weld were determined. The thin film sensors were Pt13Rh/Pt thermocouples; they were mounted on substrates of MCrAlY-coated superalloys, aluminum oxide, silicon carbide and silicon nitride. The entire sensor system is designed to be used on aircraft engine parts. These sensor systems, including the thin-film-to-lead-wire connectors, were tested to 1000 C.

Holanda, Raymond↗
NASA NTRS1976

Electrical termination techniques

A technical review of high reliability electrical terminations for electronic equipment was made. Seven techniques were selected from this review for further investigation, experimental work, and preliminary testing. From the preliminary test results, four techniques were selected for final testing and evaluation. These four were: (1) induction soldering, (2) wire wrap, (3) percussive arc welding, and (4) resistance welding. Of these four, induction soldering was selected as the best technique in terms of minimizing operator errors, controlling temperature and time, minimizing joint contamination, and ultimately producing a reliable, uniform, and reusable electrical termination.

Oakey, W. E.↗
NASA NTRS1985

NASA welding assessment program

A program was conducted to demonstrate the cycle life capability of welded solar cell modules relative to a soldered solar cell module in a simulated low earth orbit thermal environment. A total of five 18-cell welded (parallel gap resistance welding) modules, three 18-cell soldered modules, and eighteen single cell samples were fabricated using 2 x 4 cm silicon solar cells from ASEC, fused silica cover glass from OCLI, silver plated Invar interconnectors, DC 93-500 adhesive, and Kapton-Kevlar-Kapton flexible substrate material. Zero degree pull strength ranged from 2.4 to 5.7 lbs for front welded contacts (40 samples), and 3.5 to 6.2 lbs for back welded contacts (40 samples). Solar cell cross sections show solid state welding on both front and rear contacts. The 18-cell welded modules have a specific power of 124 W/kg and an area power density of 142 W/sq m (both at 28 C). Three welded and one soldered module were thermal cycle tested in a thermal vacuum chamber simulating a low earth orbit thermal environment.

Patterson, R. E.↗
NASA NTRS1991

Effect of thermal exposure, forming, and welding on high-temperature, dispersion-strengthened aluminum alloy: Al-8Fe-1V-2Si

The feasibility of applying conventional hot forming and welding methods to high temperature aluminum alloy, Al-8Fe-1V-2Si (FVS812), for structural applications and the effect of thermal exposure on mechanical properties were determined. FVS812 (AA8009) sheet exhibited good hot forming and resistance welding characteristics. It was brake formed to 90 deg bends (0.5T bend radius) at temperatures greater than or equal to 390 C (730 F), indicating the feasibility of fabricating basic shapes, such as angles and zees. Hot forming of simple contoured-flanged parts was demonstrated. Resistance spot welds with good static and fatigue strength at room and elevated temperatures were readily produced. Extended vacuum degassing during billet fabrication reduced porosity in fusion and resistance welds. However, electron beam welding was not possible because of extreme degassing during welding, and gas-tungsten-arc welds were not acceptable because of severely degraded mechanical properties. The FVS812 alloy exhibited excellent high temperature strength stability after thermal exposures up to 315 C (600 F) for 1000 h. Extended billet degassing appeared to generally improve tensile ductility, fatigue strength, and notch toughness. But the effects of billet degassing and thermal exposure on properties need to be further clarified. The manufacture of zee-stiffened, riveted, and resistance-spot-welded compression panels was demonstrated.

Kennedy, J. R.↗
NASA NTRS1973

Welding blades to rotors

A process is described to form T-joints between dissimilar thickness parts by magnetic force upset welding. This type of resistance welding is used to join compressor and turbine parts which thereby reduces the weight and cost of jet engines.

Hoklo, K. H.↗
NASA NTRS1972

State-of-technology for joining TD-NiCr sheet.

At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding (EBW), gas-tungsten arc welding (GTAW), diffusion welding (DFW), resistance spot welding (RSW), resistance seam welding (RSEW), and brazing. Roll welding (RW) and explosion welding (EXW) have not been developed to the point where they can be used to make sound welds in TD-NiCr. Joining work that has previously been done on TD-NiCr by various organizations, both privately supported and under Air Force and NASA contracts, is described in this summary. Current work is also described that is being done at General Dynamics/Convair (under NASA contract) and at NASA/Lewis to develop and evaluate DFW, RSW, RSEW, and brazing. Preliminary comparisons of joining processes are made for typical applications. A brief description of the manufacture of TD-NiCr sheet by a recently standardized process (under NASA contract) also is given.

Holko, K. H.↗
NASA NTRS1992

Infrared Thermography For Welding

Infrared imaging and image-data-processing system shows temperatures of joint during welding and provides data from which rates of heating and cooling determined. Information used to control welding parameters to ensure reliable joints, in materials which microstructures and associated metallurgical and mechanical properties depend strongly on rates of heating and cooling. Applicable to variety of processes, including tungsten/inert-gas welding; plasma, laser, and resistance welding; cutting; and brazing.

Gilbert, Jeffrey L.↗
NASA NTRS1982

Annular Electrode Improves Solar-Cell Welds

Improved method of electrical-resistance welding of solar-cell inter-connections developed by using an annular welding-electrode shape. Improved weld electrode consists of two coaxial cylinders, outer one with annular cross section and inner one with circular cross section. Possible annular weld-electrode configurations result in better quality welds for interconnecting solar-array elements.

Baraona, C. R.↗
NASA NTRS1982

Adaptive materials processing

New sensors for both arc welding and resistance spot welding processes were studied. For arc welding, the arc itself is used as the sensor. Minor changes in both composition and geometry of the plasma result in fluctuations in the arc voltage. While the process as currently employed is an off-line system, development of an on-line process controller would be possible once the optimum analysis technique is developed. It has been shown that for resistance spot welding, the dynamic resistance of the weld joint can be correlated to growth of the fusion zone. It is indicated that this technique is not as useful for projection welds as for spot welds.

Eager, T. W.↗