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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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All sourcesNASA NTRSDOE OSTI
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, gas-tungsten arc welding, diffusion welding, resistance spot welding, resistance seam welding, and brazing. The strengths of the welds made by the various processes show considerable variation, especially at elevated temperatures. Most of the fusion welding processes tend to give weak welds at elevated temperatures (with the exception of fusion-type resistance spotwelds). However, solid-state welds have been made with parent metal properties. The process used for a specific application will be dictated by the specific joint requirements. In highly stressed joints at elevated temperatures, one of the solid-state processes, such as DFW, RSW (solid-state or fusion), and RSEW, offer the most promise.

Holko, K. H.↗
NASA NTRS1973

Development of forming and joining technology for TD-NiCr sheet

Forming joining techniques and properties data were developed for thin-gage TD-NiCr sheet in the recrystallized and unrecrystallized conditions. Theoretical and actual forming limit data are presented for several gages of each type of material for five forming processes: brake forming, corrugation forming, joggling, dimpling and beading. Recrystallized sheet can be best formed at room temperature, but unrecrystallized sheet requires forming at elevated temperature. Formability is satisfactory with most processes for the longitudinal orientation but poor for the transverse orientation. Dimpling techniques require further development for both material conditions. Data on joining techniques and joint properties are presented for four joining processes: resistance seam welding (solid-state), resistance spot welding (solid-state), resistance spot welding (fusion) and brazing. Resistance seam welded (solid-state) joints with 5t overlap were stronger than parent material for both material conditions when tested in tensile-shear and stress-rupture. Brazing studies resulted in development of NASA 18 braze alloy (Ni-16Cr-15Mo-8Al-4Si) with several properties superior to baseline TD-6 braze alloy, including lower brazing temperture, reduced reaction with Td-Ni-Cr, and higher stress-rupture properties.

Torgerson, R. T.↗
NASA NTRS2006

Techniques for Connecting Superconducting Thin Films

Several improved techniques for connecting superconducting thin films on substrates have been developed. The techniques afford some versatility for tailoring the electronic and mechanical characteristics of junctions between superconductors in experimental electronic devices. The techniques are particularly useful for making superconducting or alternatively normally conductive junctions (e.g., Josephson junctions) between patterned superconducting thin films in order to exploit electron quantum-tunneling effects. The techniques are applicable to both low-Tc and high-Tc superconductors (where Tc represents the superconducting- transition temperature of a given material), offering different advantages for each. Most low-Tc superconductors are metallic, and heretofore, connections among them have been made by spot welding. Most high-Tc superconductors are nonmetallic and cannot be spot welded. These techniques offer alternatives to spot welding of most low-Tc superconductors and additional solutions to problems of connecting most high-Tc superconductors.

Mester, John↗
NASA NTRS1972

Weld-brazing - a new joining process

A joining process designated weld brazing which combines resistance spot welding and brazing has been developed. Resistance spot welding is used to position and align the parts as well as to establish a suitable faying surface gap for brazing. Fabrication is then completed by capillary flow of the braze alloy into the joint. The process has been used successfully to fabricate Ti-6Al-4V titanium alloy joints using 3003 aluminum braze alloy. Test results obtained on single overlap and hat-stiffened structural specimens show that weld brazed joints are superior in tensile shear, stress rupture, fatigue, and buckling than joint fabricated by spotwelding or brazing. Another attractive feature of the process is that the brazed joints is hermetically sealed by the braze material.

Bales, T. T.↗
NASA NTRS1973

Weld-brazing of titanium

A joining process, designated weld-brazing, which combines resistance spot-welding and brazing has been developed at the NASA Langley Research Center. Resistance spot-welding is employed to position and aline the parts and to establish a suitable faying surface gap for brazing and contributes to the integrity of the joint. Brazing enhances the properties of the joint and reduces the stress concentrations normally associated with spotwelds. Ti-6Al-4V titanium alloy joints have been fabricated using 3003 aluminum braze both in a vaccum furnace and in a retort containing an inert gas environment.

Bales, T. T.↗
NASA NTRS1984

Bending fatigue of electron-beam-welded foils. Application to a hydrodynamic air bearing in the Chrysler/DOE upgraded automotive gas tubine engine

A hydrodynamic air bearing with a compliment surface is used in the gas generator of an upgraded automotive gas turbine engine. In the prototype design, the compliant surface is a thin foil spot welded at one end to the bearing cartridge. During operation, the foil failed along the line of spot welds which acted as a series of stress concentrators. Because of its higher degree of geometric uniformity, electron beam welding of the foil was selected as an alternative to spot welding. Room temperature bending fatigue tests were conducted to determine the fatigue resistance of the electron beam welded foils. Equations were determined relating cycles to crack initiation and cycles to failure to nominal total strain range. A scaling procedure is presented for estimating the reduction in cyclic life when the foil is at its normal operating temperature of 260 C (500 F).

Saltsman, J. F.↗
NASA NTRS1979

Beam builder for space fabrication

Construction of a beam builder for producing triangular truss aluminum beams for use on large space structures is described. The machine will fabricate 0.04 cm thick 2024-T3 aluminum alloy into beams weighing 1.265 kg-m with side braces spot-welded to end caps to fabricate a triangular truss configuration up to 305 m long. The design characteristics, the electrical subsystems, the power requirements of the spot welding equipment, and the computer system for coordinating the motion of the Yoder rolling mills for forming caps from aluminum coils are described. Spot welding was compared with ultrasonic welding, stapling, wire stitching, riveting, grommets, stamp-lok, and pierce and fold joining methods with respect to ease of operation, safety, practicality, and ease of energy consumption. The beam builder will be evaluated to identify design requirements which can be utilized for the space flight version of its concept.

Ehl, J. H.↗
NASA NTRS1944

Fatigue Strength and Related Characteristics of Joints in 24s-t Alclad Sheet

Report includes tension fatigue test results on the following types of samples of 0.040-inch alclad 24s-t: (1) monoblock sheet samples as received and after a post-aging heat treatment, (2) "sheet efficiency" samples (two equally stressed sheets joined by a single transverse row of spot welds) both as received and after post-aging, (3) spot-welded lap-joint samples as received and after post-aging, and (4) roll-welded lap-joint samples. (author)

Russell, H W↗
NASA NTRS1995

Foil Patches Seal Small Vacuum Leaks

Report discloses technique to patch holes in nickel-alloy rocket-engine nozzle parts prior to vacuum brazing. Technique involves lightly spot-welding nickel foil 0.002 in. thick over hole patched, then spot-welding corrosion-resistant steel foil of same thickness over nickel foil. Once patches subject to pressure and temperature of vacuum brazing, nickel foil diffuses to bond with nickel-alloy nozzle, making vacuum-tight seal.

Spiegel, Kirk W.↗
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 NTRS1976

Capillary flow weld-bonding

The invention of a weld-bonding technique for titanium plates was described. This involves fastening at least two plates of titanium together using spot-welding and applying a bead of adhesive along the edge of the resistance spot-welded joint which upon heating, flows and fills the separation between the joint components.

Vaughan, R. W.↗
NASA NTRS1982

Controlling Electron-Beam-Weld Focus

Control loop measures weld-spot temperature to regulate focus current. Square-wave generator modulates current in electron-beam focus coil so that focal point is varied between points slightly above and below surface of weld. Sensor detects intensity of light emitted by weld, proportional to fourth power of temperature at hottest part of weld spot. Sensor signal is detected by chopper demodulator synchronized by square-wave generator, to determine whether average position of focal point is higher than, coincident with, or lower than optimum point; and focus coil current is adjusted accordingly.

Coate, F. M.↗
NASA NTRS1972

Development of the weldbond process for joining titanium

High quality resistance spot welds were produced by welding through epoxy adhesive on titanium alloys. Weldbond joints were consistently stronger than those of either mechanical fasteners, structural adhesive bonds, or mechanical fasteners with adhesive at the joint interface. Weldbond joints and/or spot weld joints showed superior strength at all temperature ranges as compared to other joints tested.

Fields, D.↗
NASA NTRS1939

The Effects of Some Surface Irregularities on Wing Drag

The N.A.C.A. has conducted tests to provide more complete data than were previously available for estimating the effects of common surface irregularities on wing drag. The irregularities investigated included: brazier-head and countersunk rivets, spot welds, several types of sheet-metal joints, and surface roughness. Tests were also conducted to determine the over-all effect of manufacturing irregularities incidental to riveted aluminum alloy and to spot-welded stainless-steel construction. The tests were made in the 8-foot high speed wind tunnel at Reynolds Numbers up to 18,000,000. The results show that any of the surface irregularities investigated may increase wing drag enough to have important adverse effects on high-speed performance and economy. A method of estimating increases in wing drag caused by brazier-head rivets and lapped joints under conditions outside the range of the tests is suggested. Estimated drag increases due to rivets and lapped joints under conditions outside the range of the tests is suggested. Estimated drag increases due to rivets and lapped joints on a wing of 20-foot chord flying at 250 miles per hour are shown.

Drag, Manley↗
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 NTRS1985

Advances in Joining Techniques Used in Development of SPF/DB Titanium Sandwich Reinforced with Metal Matrices

Three and four-sheet expanded titanium sandwich sheets have been developed at Douglas Aircraft Company, a division of McDonnell Douglas Corporation, under contract to NASA Langley Research Center. In these contracts, spot welding and roll seam welding are used to join the core sheets. These core sheets are expanded to the face sheets and diffusion bonded to form various type cells. The advantages of various cell shapes and the design parameters for optimizing the wing and fuselage concepts are discussed versus the complexity of the spot weld pattern. In addition, metal matrix composites of fibers in an aluminum matrix encapsulated in a titanium sheath are aluminum brazed successfully to the titanium sandwich face sheets. The strength and crack growth rate of the superplastic-formed/diffusion bonded (SPF/DB) titanium sandwich with and without the metal matrix composites are described.

Fischler, J. E.↗
NASA NTRS1989

The transient behavior of weldpools with a deformed free surface

Transient heat transfer, fluid flow and phase change in a weldpool with a deformed free surface are modeled using a two-dimensional coordinate transfornmation. The theoretical approach makes it possible to accurately model high Marangoni number flows even when the free surface is not horizontal. The method is used to examine the role of surface deformation and surface tension forces in controlling weld penetration during cathode spot welding of steel and aluminum. The calculated flow fields, temperature distributions and weldpool shapes are consistent with experimental findings, and are in reasonable agreement with previously published modeling efforts.

Thompson, M. E.↗