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The complex Saturn S-2 welding processes and procedures required considerable development and refinement to establish a production capability that could consistently produce aluminum alloy welds within specified requirements. The special processes and techniques are defined that were established for the welding of gore-to-gore and manhole- or closeout-to-gore.
A narrow heat source raises the temperature of a spot on a solid piece of material like metal. The high temperature of the spot decreases with distance from the spot. This is true whether the heat source is an arc, a flame, an electron beam, a plasma jet, a laser beam, or any other source of intense, narrowly defined heat. Stress and strain fields around a moving heat source are organized into a coherent visible system. It is shown that five stresses act across the weld line in turn as an arc passes. Their proportions and positions are considerably altered by weld parameters or condition changes. These pushes and pulls affect the metallurgical character and integrity of the weld area even when there is no apparent difference between after-the-fact examples.
A plasma arc welding torch is described wherein a plasma gas is directed through the body of the welding torch and out of the body across the tip of the welding electrode disposed at the forward end of the body. The plasma gas is provided with a vortexing motion prior to exiting the body by a vortex motion imparting member which is mounted in an orifice housing member and carried in the forward portion of the torch body. The orifice housing member is provided with an orifice of an predetermined diameter through which the electric arc and the plasma gas exits.
As a consequence of preparations concerning the International Space Welding Experiment (ISWE), studies were performed to better understand the effect of molten metal contact and electron beam impingement with various fabrics for space suit applications. The question arose as to what would occur if the electron beam from the Ukrainian Universal Hand Tool (UHT) designed for welding in space were to impinge upon a piece of Nextel AF-62 ceramic cloth designed to withstand temperatures up to 1427 C. The expectation was that the electron beam would lay down a static charge pattern with no damage to the ceramic fabric. The electron beam is capable of spraying the fabric with enough negative charge to repel further electrons from the fabric before significant heating occurs. The static charge pattern would deflect any further charge accumulation except for a small initial amount of leakage to the grounded surface of the welder. However, when studies were made of the effect of the electron beam on the insulating ceramic fabric it was surprisingly found that the electron beam did indeed burn through the ceramic fabric. It was also found that the shorter electron beam standoff distances had longer burnthrough times than did some greater electron beam standoff distances. A possible explanation for the longer burnthrough times for the small electron beam standoff distance would be outgassing of the fabric which caused the electron beam hand-tool to cycle on and off to provide some protection for the cathodes. The electron beam hand tool was observed to cycle off at the short standoff distance of two inches likely due to vapors being outgassed. During the electron beam welding process there is an electron leakage, or current leakage, flow from the fabric. A static charge pattern is initially laid down by the electron beam current flow. The static charge makes up the current leakage flow which initially slightly heats up the fabric. The initially laid down surface charge leaks a small amount of current. The rate at which the current charge leaks from the fabric controls how fast the fabric heats up. As the ceramic fabric is heated it begins to outgass primarily from contamination/impurities atoms or molecules on and below the fabric surface. The contaminant gases ionize to create extra charge carriers and multiply a current of electrons. The emitted gas which ionized in the electron leakage flow promotes further leakage. Thus, the small leakage of charge from the fabric surface is enhanced by outgassing. When the electron beam current makes up the lost current, the incoming electrons heat the fabric and further enhance the outgassing. The additional leakage promotes additional heating up of the ceramic fabric. The electrons bound to the ceramic fabric surface leak off more and more as the surface gets hotter promoting even greater leakage. The additional electrons that result also gain energy in the field and produce further electrons. Eventually the process becomes unstable and accelerates to the point where a hole is burned through the fabric.
Two concepts, stationary cooling and trailing cooling, were proposed to prevent weld intersection cracking. Finite element analysis was used to demonstrate the potential effectiveness of those two concepts. Both stationary and trailing heat sink setups were proposed for preventing intersection cracking. The cooling media could be liquid nitrogen, or pressured air knife. Welding experiments on the small test panel with the localized heat sink confirmed the feasibility of using such a stationary cooling technique. The required cooling was achieved in this test panel. Systematic welding experiments should be conducted in the future to validate and refine the heat sink technique for preventing intersection cracking.
Through the implementation of friction stir welding, the safety, reliability, and producibility of the external tank is enhanced. Such fusion procedures are accomplished with the use of a short barrel weld tool or a long barrel weld tool. Forecasted developments in the fusion tooling field include the advent of a universal tool which is capable to fusing all barrel configurations. A wide array of mechanical and electrical controls are described for such a device.
Heavy Inclusions (HI) were detected for the first time by radiographic examination in aluminum alloy 2219forging/2195plate (advancing/retreating side) Friction Sir Welds (FSW) for the Space Shuttle External Tank (ET) Program. Radiographic HI indications appear as either small (approx.0.005"-0.025") individual particles or clusters of small particles. Initial work was performed to verify that the HI was not foreign material or caused by FSW pin tool debris. That and subsequent elemental analysis determined that the HI were large agglomerations of Al2Cu (theta phase), which is the strengthening precipitate in Al2219. A literature search on that subject determined that the agglomeration of phase has also been found in Al2219 bead on plate FSW [Ref. 1]. Since this was detected in ET space flight hardware, an investigative study of the effect of agglomerated theta phase particles in FSW Al2219f/2195p was performed. Numerous panels of various lengths were welded per ET weld procedures and radiographically inspected to determine if any HI was detected. Areas that had HI were sampled for room temperature and cyclic cryogenic (-423F) tensile testing and determined no significant adverse affect on mechanical properties when compared to test specimens without HI and historical data. Fracture surface examination using the Scanning Electron Microscope (SEM) revealed smaller phase agglomerations undetectable by radiographic inspection dispersed throughout the Al2219f/2195p FSW. This indicates that phase agglomeration is inherent to the Al2219f/2195p FSW process and only rarely creates agglomerations large enough to be detected by radiography. HI has not been observed in FSW of plate to plate material for either Al2219 or AL2195.
Computer welding skate for automatic gas tungsten- arc welding of contoured or double-contoured parts, providing control without touching work surface with transducers
Relationships between weld quality and nonvacuum electron beam welding procedures
An improved procedure for arc spot welding uses the SIGMA /Submerged Inert Gas Metallic Arc/ method. This has resulted in welds of higher quality than are obtainable by conventional meansc
The ATD phase of the PAWS program ended in November 1992 and the follow-on ManTech program was started in September 1993. The system will be industrially hardened during the first year of this program. Follow-on years will focus upon the transition into specific end-user sites. These implementations will also expand the system into other welding processes (e.g. FCAW, GTAW, PAW). In addition, the architecture is being developed for application to other non-welding robotic processes (e.g. inspection, surface finishing). Future development is anticipated to encompass hardening for extreme environments, expanded exception handling techniques, and application to a range of manipulators.
In the Friction Stir Welding (FSW) process a rotating pin inserted into a seam literally stirs the metal from each side of the seam together. It is proposed that the flow in the vicinity of the pin-tool comprises a primary rapid shear over a cylindrical envelope covering the pin-tool and a relatively slow secondary flow taking the form of a ring vortex about the tool circumference. This model is consistent with a plastic characterization of metal flow, where discontinuities in shear flow are allowed but not viscous effects. It is consistent with experiments employing several different kinds of tracer: atomic markers, shot, and wire. If a rotating disc with angular velocity w is superposed on a translating continuum with linear velocity omega, the trajectories of tracer points become circular arcs centered upon a point displaced laterally a distance v/omega from the center of rotation of the disc in the direction of the advancing side of the disc. In the present model a stream of metal approaching the tool (taken as the coordinate system of observation) is sheared at the slip surface, rapidly rotated around the tool, sheared again on the opposite side of the tool, and deposited in the wake of the tool. Local shearing rates are high, comparable to metal cutting in this model. The flow patterns in the vicinity of the pin-tool determine the level of homogenization and dispersal of contaminants that occurs in the FSW process. The approaching metal streams enfold one another as they are rotated around the tool. Neglecting mixing they return to the same lateral position in the wake of the tool preserving lateral tracer positions as if the metal had flowed past the tool like an extrusion instead of being rotated around it. (The seam is, however, obliterated.) The metal stream of thickness approximately that of the tool diameter D is wiped past the tool at elevated temperatures drawn out to a thickness of v/2(omega) in the wiping zone. Mixing distances in the wiping zone are multiplied in the unfolded metal. Inhomogeneities on a smaller scale than the mixing length are obliterated, but structure on a larger scale may be transmitted to the wake of a FSW weld.
Welding technique advances and testing of bond integrity for microcircuit fabrication
Relationships between radiographic quality and nonvacuum electron beam welding procedures
Welding skate with computerized torch angle and speed control maintained without mechanical, electromechanical or photoelectric transducers
Tests to develop biaxial strength allowables for MIG and TIG welds in aluminum alloys
The special processes and techniques are defined that were established for the vertical panel trim and weld operations to assemble Saturn S-2 cylinder assemblies.
Special processes and techniques are described for the circumferential welding of Saturn 2 cylinder and bulkhead assemblies to complete the LO2 and LH2 tankage and to maximize efficiency and personnel performance during S-2 follow-on or restart activities. The processes are only applicable to aluminum alloys within the 2000 series.