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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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New welding skate concept for automatic TIG welding of contoured or double-contoured parts combines lightweight welding apparatus with electrical circuitry which computes the desired torch angle and positions a torch and cold-wire guide angle manipulator.
Gas/tungsten-arc welding torch supports electrode at center while enabling viewing of weld area along torch axis. Gas torch accommodates lens and optical fibers, all part of vision system for welding robot. Welding torch includes spoked structure in central bore of optical body. Structure supports welding electrode, carries electric current to it, and takes heat away from it. Spokes formed by drilling six holes 60 degrees apart around center line of torch.
Report presents results of study of variable-polarity plasma arc (VPPA) welding of aluminum alloy 2219. Consists of two parts: Examination of effects of microsegregation and transient weld stress on macrosegregation in weld pool and, electrical characterization of straight- and reverse-polarity portions of arc cycle.
Sterilization effects on soldered and welded joints, electronic equipment processes and materials, electric connectors, and wiring and cabling accessories
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.
Interconnect materials and designs for use with ultrathin silicon solar cells are discussed, as well as the results of an investigation of the applicability of parallel-gap resistance welding for interconnecting these cells. Data relating contact pull strength and cell electrical degradation to variations in welding parameters such as time, voltage and pressure are presented. Methods for bonding ultrathin cells to flexible substances and for bonding thin (75 micrometers) covers to these cells are described. Also, factors influencing fabrication yield and approaches for increasing yield are discussed. The results of vacuum thermal cycling and thermal soak tests on prototype ultrathin cell test coupons and one solar module blanket are presented.
Contact tips for gas/metal arc welding (GMAW) fabricated from oxygen-free copper. Prototype tips tested in robotic welding, for which application intended. Reduces electrical erosion, increases electrical conductivity, and reduces mechanical wear. Productivity of robotic welding increases while time during welding interrupted for removal and replacement of contact tips minimal. Improves alignment of joints and filler metal, reducing rate of rejection and repair of unacceptable weldments. Utility extends beyond aerospace industry to mass production of various types of hardware, including heavy off-highway construction equipment.
Electrical maintenance program for welding equipment and machine tools
A combined experimental and analytical program was conducted to examine the effects of inlet turbulence and airfoil heat transfer. The experimental portion of the study was conducted in a large-scale (approx. 5X engine), ambient temperature, rotating turbine model configured in both single-stage and stage-and-a-half arrangements. Heat transfer measurements were obtained using low-conductivity airfoils with miniature thermocouples welded to a thin, electrically heated surface skin. Heat transfer data were acquired for various combinations of low or high inlet turbulence intensity, flow coefficient, first stator-rotor axial spacing, Reynolds number and relative circumferential position of the first and second stators. Aerodynamic measurements obtained include distributions of the mean and fluctuating velocities at the turbine inlet and, for each airfoil row, midspan airfoil surface pressures and circumferential distributions of the downstream steady state pressures and fluctuating velocities. Results include airfoil heat transfer predictions produced using existing 2-D boundary layer computation schemes and an examination of solutions of the unsteady boundary layer equations.
This is Volume 3 - Heat Transfer Data Tabulation (65 percent Axial Spacing) of a combined experimental and analytical program which was conducted to examine the effects of inlet turbulence on airfoil heat transfer. The experimental portion of the study was conducted in a large-scale (approximately 5X engine), ambient temperature, rotating turbine model configured in both single stage and stage-and-a-half arrangements. Heat transfer measurements were obtained using low-conductivity airfoils with miniature thermocouples welded to a thin, electrically heated surface skin. Heat transfer data were acquired for various combinations of low or high inlet turbulence intensity, flow coefficient, first-stator/rotor axial spacing, Reynolds number and relative circumferential position of the first and second stators.
A combined experimental and analytical program was conducted to examine the effects of inlet turbulence on airfoil heat transfer. The experimental portion of the study was conducted in a large-scale (approx 5X engine), ambient temperature, rotating turbine model configured in both single stage and stage-and-a-half arrangements. Heat transfer measurements were obtained using low-conductivity airfoils with miniature thermcouples welded to a thin, electrically heated surface skin. Heat transfer data were acquired for various combinations of low or high inlet turbulence intensity, flow coefficient, first-stator/rotor axial spacing, Reynolds number and relative circumferential position of the first and second stators. Aerodynamic measurements obtained as part of the program include distributions of the mean and fluctuating velocities at the turbine inlet and, for each airfoil row, midspan airfoil surface pressures and circumferential distributions of the downstream steady state pressures and fluctuating velocities. Analytical results include airfoil heat transfer predictions produced using existing 2-D boundary layer computation schemes and an examination of solutions of the unsteady boundary layer equations. The results are reported in four separate volumes, of which this is Volume 2: Heat Transfer Data Tabulation; 15 Percent Axial Spacing.
A combined experimental and analytical program was conducted to examine the effects of inlet turbulence on airfoil heat transfer. Heat transfer measurements were obtained using low conductivity airfoils with miniature thermocouples welded to a thin, electrically heated surface skin. Heat transfer data were acquired for various combinations of low or high inlet turbulence intensity, flow coefficient (incidence), first-stator/rotor axial spacing, Reynolds number, and relative circumferential position of the first and second stators. Aerodynamic measurements include distributions of the mean and fluctuating velocities at the turbine inlet and, for each airfoil row, midspan airfoil surface pressures and circumferential distributions of the downstream steady state pressures and fluctuating velocities. Analytical results include airfoil heat transfer predictions and a examination of solutions of the unstead boundary layer equipment.
Compact resistance-welding pinch gun lets one operator do jobs formerly needing two workers. Light in weight and produces repeatable, high-quality weld joints. Welding-electrode head rotates for easy positioning. Lever at top of handle activates spring to pinch electrodes together at preset welding force. Button at bottom of handle activates welding current. Cables supply electrical power.
The lignin content of wood, paper pulp or other material containing lignin (such as filter paper soaked in black liquor) is more readily determined by flash pyrolysis of the sample at approximately 550.degree. C. in a reducing atmosphere of hydrogen or in an inert atmosphere of helium followed by a rapid analysis of the product gas by a mass spectrometer. The heated pyrolysis unit as fabricated comprises a small platinum cup welded to an electrically-heated stainless steel ribbon with control means for programmed short duration (1.5 sec, approximately) heating and means for continuous flow of hydrogen or helium. The pyrolysis products enter an electron-ionization mode mass spectrometer for spectral evaluation. Lignin content is obtained from certain ratios of integrated ion currents of many mass spectral lines, the ratios being linearly related to the Kappa number of Klason lignin.
An improvement has been made to the design of the hollow cathode geometry that was created for the rare-earth electron emitter described in Compact Rare Earth Emitter Hollow Cathode (NPO-44923), NASA Tech Briefs, Vol. 34, No. 3 (March 2010), p. 52. The original interior assembly was made entirely of graphite in order to be compatible with the LaB6 material, which cannot be touched by metals during operation due to boron diffusion causing embrittlement issues in high-temperature refractory materials. Also, the graphite tube was difficult to machine and was subject to vibration-induced fracturing. This innovation replaces the graphite tube with one made out of refractory metal that is relatively easy to manufacture. The cathode support tube is made of molybdenum or molybdenum-rhenium. This material is easily gun-bored to near the tolerances required, and finish machined with steps at each end that capture the orifice plate and the mounting flange. This provides the manufacturability and robustness needed for flight applications, and eliminates the need for expensive e-beam welding used in prior cathodes. The LaB6 insert is protected from direct contact with the refractory metal tube by thin, graphite sleeves in a cup-arrangement around the ends of the insert. The sleeves, insert, and orifice plate are held in place by a ceramic spacer and tungsten spring inserted inside the tube. To heat the cathode, an insulating tube is slipped around the refractory metal hollow tube, which can be made of high-temperature materials like boron nitride or aluminum nitride. A screw-shaped slot, or series of slots, is machined in the outside of the ceramic tube to constrain a refractory metal wire wound inside the slot that is used as the heater. The screw slot can hold a single heater wire that is then connected to the front of the cathode tube by tack-welding to complete the electrical circuit, or it can be a double slot that takes a bifilar wound heater with both leads coming out the back. This configuration replaces the previous sheathed heater design that limited the cycling-life of the cathode.
A report describes the use of advanced electromagnetic probes to measure the dimensions, the spatial distribution of electrical conductivity, and related other properties of friction stir welds (FSWs) between parts made of the same or different aluminum alloy(s). The probes are of the type described in in another Tech Brief. To recapitulate: A probe of this type is essentially an eddy-current probe that includes a primary (driver) winding that meanders and multiple secondary (sensing) windings that meander along the primary winding. Electrical conductivity is commonly used as a measure of heat treatment and tempering of aluminum alloys, but prior to the development of these probes, the inadequate sensitivity and limited accuracy of electrical-conductivity probes precluded such use on FSWs between different aluminum alloys, and the resolution of those probes was inadequate for measurement of FSW dimensions with positions and metallurgical properties. In contrast, the present probes afford adequate accuracy and spatial resolution for the purposes of measuring the dimensions of FSW welds and correlating spatially varying electrical conductivities with metallurgical properties, including surface defects.
The present work describes parallel gap welding as used for joining solar cells to the cell interconnect system. Sample preparation, weldable cell parameter evaluation, bond scheduling, bond strength evaluation, and bonding and thermal shock tests are described. A range of weld schedule parameters - voltage, time, and force - can be identified for various cell/interconnect designs that will provide adequate bond strengths and acceptably small electrical degradation. Automation of solar array welding operations to a significant degree has been achieved in Europe and will be receiving increased attention in the U.S. to reduce solar array fabrication costs.
Mechanical testing and metallographic examination of aluminum to copper coldwelded joints after thermal exposure - SNAP-8 electrical terminal