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At least 613 records · Page 34

All sources NASA NTRS DOE OSTI

NASA NTRS2006

Damage Tolerance Analysis of Space Shuttle External Tank Lug Fillet Welds Using NASGRO

The damage tolerance of the External Tank (ET) lug welds were reassessed because of an increase in the loads due to the removal of the protuberance air load (PAT.,) ramp. The analysis methods included detailed finite element analysis (FEA) of the ET welded lugs and FEA of the lug weld test configuration. The FEA results were used as input to the crack growth analysis code NASGRO to calculate the mission life capability of the ET lug welds and to predict the number of cycles to failure in the lug weld testing. The presentation presents the method of transferring the FEM results to the NASGRO model and gives correlations between FEM and NASGRO stress intensity calculations.

Allen, Phillip A.↗

NASA NTRS2001

Friction pull plug welding: top hat plug design

Friction Pull Plug Welding is a solid state repair process for defects up to one inch in length, only requiring single sided tooling, or outside skin line (OSL), for preferred usage on flight hardware. The most prevalent defect associated with Friction Pull Plug Welding (FPPW) was a top side or inside skin line (ISL) lack of bonding. Bonding was not achieved at this location due to the reduction in both frictional heat and welding pressure between the plug and plate at the end of the weld. Thus, in order to eliminate the weld defects and increase the plug strength at the plug `top` a small `hat` section is added to the pull plug for added frictional heating and pressure.

Coletta, Edmond R.↗

NASA NTRS2002

Friction pull plug welding: top hat plug design

Coletta, Edmond R.↗

NASA NTRS2007

Welding Development: Marshall Space Flight Center

This paper presents the basic understanding of the friction stir welding process. It covers process description, pin tool operation and materials, metal flow theory, mechanical properties, and materials welded using the process. It also discusses the thermal stir welding process and the differences between thermal stir and friction stir welding. MSFC weld tools used for development are also presented.

Ding, Jeff↗

NASA NTRS2008

Elastic-Plastic Fracture Mechanics Analysis of Critical Flaw Size in ARES I-X Flange-to-Skin Welds

NASA's Ares 1 Upper Stage Simulator (USS) is being fabricated from welded A516 steel. In order to insure the structural integrity of these welds it is of interest to calculate the critical initial flaw size (CIFS) to establish rational inspection requirements. The CIFS is in turn dependent on the critical final flaw size (CFS), as well as fatigue flaw growth resulting from transportation, handling and service-induced loading. These calculations were made using linear elastic fracture mechanics (LEFM), which are thought to be conservative because they are based on a lower bound, so called elastic, fracture toughness determined from tests that displayed significant plasticity. Nevertheless, there was still concern that the yield magnitude stresses generated in the flange-to-skin weld by the combination of axial stresses due to axial forces, fit-up stresses, and weld residual stresses, could give rise to significant flaw-tip plasticity, which might render the LEFM results to be non-conservative. The objective of the present study was to employ Elastic Plastic Fracture Mechanics (EPFM) to determine CFS values, and then compare these values to CFS values evaluated using LEFM. CFS values were calculated for twelve cases involving surface and embedded flaws, EPFM analyses with and without plastic shakedown of the stresses, LEFM analyses, and various welding residual stress distributions. For the cases examined, the computed CFS values based on elastic analyses were the smallest in all instances where the failures were predicted to be controlled by the fracture toughness. However, in certain cases, the CFS values predicted by the elastic-plastic analyses were smaller than those predicted by the elastic analyses; in these cases the failure criteria were determined by a breakdown in stress intensity factor validity limits for deep flaws (a greater than 0.90t), rather than by the fracture toughness. Plastic relaxation of stresses accompanying shakedown always increases the calculated CFS values compared to the CFS values determined without shakedown. Thus, it is conservative to ignore shakedown effects.

Chell, G. Graham↗

NASA NTRS2008

Assessment of the LC-2 Prelaunch Fatigue Spectra of the CM-to-SM Flange Weld

The pad stay and rollout components of the Ares I-X life cycle can generate cyclic stress oscillations to the vehicle that could initiate and grow fatigue cracks from weld defects. The Ares I-X Project requested that a study be performed to determine if stabilization of the vehicle is required to reduce the stresses that could initiate and grow fatigue cracks at the flange-to-skin weld of the Command Module (CM) and Service Module (SM) interface. A fatigue crack growth analysis was conducted that used loads (LC-2) and stress analyses developed by the Ares I-X Project and utilized material data and analysis methods developed by a critical initial flaw size (CIFS) analysis conducted by NASA Engineering and Safety Center (NESC) for the Upper Stage Simulator (USS) of the Ares I-X vehicle. A full CIFS analysis for the CM-to-SM flange-to-skin weld was not performed because the full flight spectrum was not provided and was not necessary to answer the question posed by the Ares I-X Project. Instead, an approach was developed to determine if the crack growth due to the pad stay and rollout components of the flight spectrum would adversely influence the CIFS. The approach taken used a number of conservative assumptions that eliminated the need for high-fidelity analyses and additional material testing, but still provided a bounding solution for the uncertainties of the problem. The results from this analysis indicate that the LC-2 pad stay and rollout spectrum components would not produce significant fatigue crack growth on the CM-to-SM flange-to-skin weld. Thus, from a fatigue crack growth standpoint, no stabilization is required to reduce the LC-2 pad stay and rollout cyclic stresses on the CM-to-SM flange-to-skin weld.

Dawicke, David S.↗

NASA NTRS2008

Fatigue Crack Growth in Peened Friction Stir Welds

Friction stir welding induces residual stresses that accelerates fatigue crack growth in the weld nugget. Shot peening over the weld had little effect on growth rate. Laser peening over the weld retarded the growth rate: Final crack growth rate was comparable to the base, un-welded material. Crack tunneling evident from residual compressive stresses. 2195-T8 fracture surfaces were highly textured. Texturing makes comparisons difficult as the material system is affecting the data as much as the processing. Material usage becoming more common in space applications requiring additional work to develop useful datasets for damage tolerance analyses.

Forth, Scott C.↗

NASA NTRS2009

Pin Tool Geometry Effects in Friction Stir Welding

In friction stir welding (FSW) there is significant evidence that material can take one of two different flow paths when being displaced from its original position in front of the pin tool to its final position in the wake of the weld. The geometry of the pin tool, along with the process parameters, plays an important role in dictating the path that the material takes. Each flow path will impart a different thermomechanical history on the material, consequently altering the material microstructure and subsequent weld properties. The intention of this research is to isolate the effect that different pin tool attributes have on the flow paths imparted on the FSWed material. Based on published weld tool geometries, a variety of weld tools were fabricated and used to join AA2219. Results from the tensile properties and microstructural characterization will be presented.

Querin, J. A.↗

NASA NTRS2010

Advanced Welding Applications

Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

Ding, Robert J.↗

NASA NTRS2010

Large Spun Formed Friction-Stir Welded Tank Domes for Liquid Propellant Tanks Made from AA2195: A Technology Demonstration for the Next Generation of Heavy Lift Launchers

Improving structural efficiency while reducing manufacturing costs are key objectives when making future heavy-lift launchers more performing and cost efficient. The main enabling technologies are the application of advanced high performance materials as well as cost effective manufacture processes. This paper presents the status and main results of a joint industrial research & development effort to demonstrate TRL 6 of a novel manufacturing process for large liquid propellant tanks for launcher applications. Using high strength aluminium-lithium alloy combined with the spin forming manufacturing technique, this development aims at thinner wall thickness and weight savings up to 25% as well as a significant reduction in manufacturing effort. In this program, the concave spin forming process is used to manufacture tank domes from a single flat plate. Applied to aluminium alloy, this process allows reaching the highest possible material strength status T8, eliminating numerous welding steps which are typically necessary to assemble tank domes from 3D-curved panels. To minimize raw material costs for large diameter tank domes for launchers, the dome blank has been composed from standard plates welded together prior to spin forming by friction stir welding. After welding, the dome blank is contoured in order to meet the required wall thickness distribution. For achieving a material state of T8, also in the welding seams, the applied spin forming process allows the required cold stretching of the 3D-curved dome, with a subsequent ageing in a furnace. This combined manufacturing process has been demonstrated up to TRL 6 for tank domes with a 5.4 m diameter. In this paper, the manufacturing process as well as test results are presented. Plans are shown how this process could be applied to future heavy-lift launch vehicles developments, also for larger dome diameters.

Stachulla, M.↗

DOE OSTI2021

Thermoplastic welding apparatus and related methods

Thermoplastic welding apparatus and related methods are disclosed. An example method includes providing a smart susceptor between composite parts that are to be joined via thermoplastic welding. The example method includes positioning the composite parts and the smart susceptor on a tooling surface within a cavity of a tooling apparatus and applying a seal to the composite parts and the tooling surface to form a vacuum chamber between the composite parts and the tooling surface at a welding joint of the composite parts; producing a magnetic field at the welding joint. The example method includes providing a vacuum in the vacuum chamber during a welding operation.

Matsen, Marc R.↗

DOE OSTI2023

Apparatus for a laser welding system

A laser welding system for welding a component and reducing defects in the weld by ensuring uniform, laminar gas flow over a process area of the system. The laser welding system comprises a laser for welding the component, a platform for supporting the component, an enclosure surrounding the platform, a first actuatable barrier, a second actuatable barrier, an actuator, and a controller. The enclosure includes a plurality of walls, one of the walls having an inlet and another wall having an outlet. The inlet and outlet each having an opening having a cross-sectional area for letting gas flow through. The first and second barriers are configured to modify the cross-sectional areas of the openings when actuated. The actuator is configured to actuate the barriers, and the controller is configured to direct the actuator to actuate the barriers so that the cross-sectional area of the first opening is larger than the cross-sectional area of the second opening so that a pressure at the inlet is greater than a pressure at the outlet.

Sartin, Bryan↗

DOE OSTI2019

A Novel Shim-Assisted Resistance Spot Welding Process to Improve Weldability of Medium-Mn Transformation-Induced Plasticity Steel

Medium-Mn transformation-induced plasticity steels have great potential to significantly reduce vehicle weight and improve fuel economy due to their outstanding combination of high strength and excellent ductility. One bottleneck to the application is their poor weldability resulting from their high Mn contents. In this paper, three resistance spot welding set-ups, including no shim, an interstitial-free steel shim at the faying interface (shim-in) and shims against the electrodes (shim-out), were incorporated to investigate the weldability of Fe-7Mn-0.14C medium-Mn steel. Tensile-shear, cross-tension, and microhardness tests were used to evaluate the mechanical properties of the welds. Experimental results demonstrated that the failure mode of the welds transitioned from the interfacial fracture in the case of no shim to the desired nugget pull-out fracture in the shim-out set-up, resulting in dramatical improvements in both peak loads and their corresponding extensions during the tensile-shear and cross-tension tests. In contrast, the shim-in set-up made no improvement. What can contribute to such improvement was then discussed on the basis of observed morphologies and microstructures of welds.

36 MATERIALS SCIENCE↗

DOE OSTI2025

A potential emerging issue concerning repair welding of out-of-core PWR components involving tritium exposure and 3 He retention

This paper identifies a potential but previously unrecognized risk of helium-induced embrittlement and cracking during repair welding of out-of-core pressurized water reactor (PWR) components exposed to tritium-contaminated coolant. While previous weldability concerns centered on 4 He accumulation in neutron-irradiated alloys located within the in-core or near-core regions, new measurements show that 3 He generated by tritium decay can accumulate in out-of-core components. Because hydrogen isotopes readily diffuse to grain boundaries and become trapped there, significant 3 He generation at grain boundaries may lead to cracking during weld repairs. Initial data from far-below-core PWR flux thimble tubes confirm the presence of 3 He levels above known cracking thresholds for repair welds. In conclusion, these findings indicate that out-of-core regions should be considered when defining safe weld repair windows in reactors operating for 60–100 years.

Extended PWR lifetimes↗

DOE OSTI2018

Microstructural evolution and hardness response in the laser beam welded joints of pure titanium during recrystallization and grain growth

Highlights: • The LABs and high local misorientations indicate the existence of plastic strains in the as-welded HAZ and FZ. • During heat treatment the recrystallization occurs in the HAZs, decreasing plastic strains, but it doesn't appear in the FZs. • The coarse and unstrained grains gradually replace the fine and strained ones in the HAZs during recrystallization. • The decrease of plastic strains in the HAZs during recrystallization causes the descent of average hardness values based on the strain strengthening. - Abstract: Microstructural evolution and hardness response in the laser beam welded joints of pure titanium during recrystallization and grain growth were investigated by means of electron backscatter diffraction and hardness measurement. The low-angle boundaries (LABs) and high local misorientations, in the as-welded heat affected zone (HAZ) and fusion zone (FZ), indicate the existence of plastic strains caused by the plastic strains due to the thermal stress and the non-equilibrium phase transformations. The recrystallization occurs in the HAZs during heat treatment, but the grain growth after recrystallization does not appear under the heat treatment conditions. Moreover as a result of the slightly high impurity contents in the as-welded FZ, no distinct recrystallization is found in the FZs in this work. During recrystallization in the HAZs, the coarse and unstrained grains with equiaxed shape and smooth boundary gradually consume the fine and strained ones with irregular shape and serrate boundary. Meanwhile, the LABs disappear and the low local misorientations replace the high ones in the modified grains. The recrystallization during heat treatment causes the decrease of plastic strains in the HAZs, which reflects on the descent of average hardness values based on the strain strengthening.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Macroscale property assessment and indentation characteristics of thick section friction stir welded AA 5083

The spatial gradients in microstructure have been proven to be effective in optimizing the performance of components, and several techniques have been developed to achieve this microstructure. Nevertheless, the local microstructural modification methods inevitably result in the formation of gradient microstructure leading to a variation in the property. Herein this work systematically investigates the effect of gradient microstructure formed during thick section friction stir weld Al5083 alloy on its mechanical properties. A novel macro-indentation technique, profilometer-based indentation plastometry (PIP), is utilized to capture the variation in the mechanical properties in the feedstock (rolled plate) and weld region. The feedstock exhibited a gradient microstructure owing to different stress states during rolling. Additionally, the stirring of the tool resulted in a complex material flow pattern producing a microstructure gradient in the weld region. The aspect ratio of the grains was identified as the primary factor causing variation in indentation response in the feedstock. In contrast, variation in the grain size in the weld region resulted in property variation. Overall, the stir zone has a lower yield strength (158±4MPa) than the base material (173±3MPa). In addition, microstructure heterogeneity in the stir zone resulted in lower elongation than the base material.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Model Predictive Control of GTAW Weld Pool Penetration

Weld pool penetration is a major implication of weld integrity but it is not directly measurable. The key to solving this issue is to find or create observable phenomena that can be used to derive the penetration. An innovative method has recently been proposed/developed to derive the penetration from the reflection of projected laser from an oscillating weld pool surface. Yet, in addition to the penetration, the oscillation, thus the reflection determined by it, also depends on the pulse amplitude of the current, which needs to be adjusted as the control variable to feedback control the penetration as the output. This dependence imposes a constraint on the control algorithm such that the adjustment of the control variable must be relatively slow to minimize additional sources that affect the oscillation/sensor. This restriction on the control variable adjustment also brings challenges to the identification of the dynamic model of the weld process to be controlled, which has to apply a varying control signal to stimulate the dynamics. To solve these issues, this letter proposes using a low order model to catch the dominant dynamics such that a high speed variation in the control signal can be avoided when choosing the model predictive control algorithm. This allows use of relatively poor models to determine the adjustment on the pulsing amplitude, and still achieves relatively accurate control. Experimental results verified the effectiveness of the resultant penetration control system despite the restrictions imposed by the penetration sensor, which affect the identification of high order dynamics and free adjustments of control variables.

42 ENGINEERING↗

NASA NTRSDate not supplied

Laser Beam Welding Benchmark Experiments Performed in Reduced Gravity and Vacuum

Laser beam welding (LBW) is affected by the extreme temperatures, reduced pressure, and reduced gravity present in space environments. Gravity and pressure especially influence its melt pool and solidification dynamics. A compact, modular vacuum chamber adaptable to flight platforms from parabolic to orbital currently hosts an experiment to investigate the combined influence of reduced gravity and pressure on LBW. A swappable cartridge contains a rotating platen on which customizable workpieces can be welded under vacuum, greatly increasing experimental throughput. Instrumentation includes weld and thermal cameras observing the process, thermocouples placed on workpieces, accelerometers, and vacuum sensors. Experimental data gathered during the welding process will be combined with post-flight nondestructive evaluation, metallography, and mechanical testing to provide validation datasets for computational modeling. Phase I of this effort involves a parabolic flight campaign in low gravity while an anticipated Phase II would proceed to in-space demonstration to access extended duration microgravity.

in-space welding↗