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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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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1987

Electrode support for gas arc welding torch having coaxial vision

An improved electrode mounting structure for a gas tungsten arc welding torch having a coaxial imaging system. The electrode mounting structure includes a support having a central hub and a plurality of spokes which extend from the hub generally radially with respect to the axis of the torch into supporting engagement with the interior walls of the torch. The spaces between the spokes are optical passages for transmission of light to form the image. A tubular collet holder is threadedly engaged at its upper end to the hub and extends downwardly toward the open end of the torch. The collet holder has an inwardly tapering constriction near its lower end. An electrode-retaining, tubular collet is mounted within the collet holder and has a longitudinally split and tapered end seating against the tapered constriction. A spring seats against the upper end of the collet and forces the split end against the tapered constriction to wedge the split end radially inwardly to grip the electrode within the collet.

Richardson, Richard W.↗
NASA NTRS1987

Welding arc and plasma studies using real time, multipass holographic interferometry

Flow visualization of the plasma process in a welding arc is being studied with a multipass Argon ion interferometer. High speed movies at 10,000 frames per/sec are taken. The multipass interferometer and several interferograms of the plasma near the electrode of the welding are given. Digitization of the fringes is currently done by hand.

Deason, Vance↗
DOE OSTI2017

Effect of Mo-rich Fillers in Pulsed Current Gas Tungsten Arc Welding of Inconel 718 for Improved Strength and Hot Corrosion Resistance

The formation of Laves phase in the fusion zone of Inconel 718 welds is considered to be detrimental and requires major attention, as this phase deteriorates the mechanical properties and high-temperature corrosion resistance. This present study addresses the use of current pulsing technique on the gas tungsten arc welding of 5-mm-thick Inconel 718 plates. Nb-free fillers, namely ERNiCrMo-10 and ERNiCrMo-14, are chosen for joining these plates. Microstructure studies revealed the segregation of Mo-rich phases at the inter-dendritic regions of the fusion zone of both the weldments. Further, the occurrence of detrimental Laves phase was minimized while employing Mo-rich fillers. It is inferred from the tensile studies that the fractures occurred in the parent metal for ERNiCrMo-10 filler and at the fusion zone while employing ERNiCrMo-14. Room-temperature Charpy impact studies also affirm that the impact toughness of ERNiCrMo-10 welds is significantly greater than that of ERNiCrMo-14. Hot corrosion studies were performed on the coupons by exposing them to a synthetic molten salt environment comprising Na{sub 2}SO{sub 4} + 60%V{sub 2}O{sub 5} at 800 °C for 50 h. Owing to the presence of higher amounts of Cr{sub 2}O{sub 3} and NiO, both fusion zones exhibited better hot corrosion resistance than the parent metal. The novel outcome of the study reiterates that with the use of current pulsing and Mo-rich fillers, the detrimental phase shall be controlled.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Effects of varying subatmospheric pressure on stationary plasma arc welds

An experimental study was performed examining the variation of penetration, fluid behavior, heat-affected zone and arc in plasma arc welding (PAW) with respect to subatmospheric ambient pressure. The results reveal nonlinear variation of keyhole size, time of penetration, and size of the heat-affected zone with pressure. In a restricted range of pressure, dynamic components of fluid flow directed out of the molten pool appear and have a profound effect on keyhole formation. The generated plasma arc is observed to decrease in intensity with decreasing pressure, resulting in a reduction of penetration at lower pressures.

Chin, J. J.↗
DOE OSTI2022

Crystallographic effects on transgranular chloride-induced stress corrosion crack propagation of arc welded austenitic stainless steel

Abstract The effect of crystallography on transgranular chloride-induced stress corrosion cracking (TGCISCC) of arc welded 304L austenitic stainless steel is studied on >300 grains along crack paths. Schmid and Taylor factor mismatches across grain boundaries (GBs) reveal that cracks propagate either from a hard to soft grain, which can be explained merely by mechanical arguments, or soft to hard grain. In the latter case, finite element analysis reveals that TGCISCC will arrest at GBs without sufficient mechanical stress, favorable crystallographic orientations, or crack tip corrosion. GB type does not play a significant role in determining TGCISCC cracking behavior nor susceptibility. TGCISCC crack behaviors at GBs are discussed in the context of the competition between mechanical, crystallographic, and corrosion factors.

36 MATERIALS SCIENCE↗
NASA NTRS2007

Study of Radiographic Linear Indications and Subsequent Microstructural Features in Gas Tungsten Arc Welds of Inconel 718

This study presents examples and considerations for differentiating linear radiographic indications produced by gas tungsten arc welds in a 0.05-in-thick sheet of Inconel 718. A series of welds with different structural features, including the enigma indications and other defect indications such as lack of fusion and penetration, were produced, radiographed, and examined metallographically. The enigma indications were produced by a large columnar grain running along the center of the weld nugget occurring when the weld speed was reduced sufficiently below nominal. Examples of respective indications, including the effect of changing the x-ray source location, are presented as an aid to differentiation. Enigma, nominal, and hot-weld specimens were tensile tested to demonstrate the harmlessness of the enigma indication. Statistical analysis showed that there is no difference between the strengths of these three weld conditions.

Walley, J. L.↗
DOE OSTI2010

Set up an Arc Welding Code with Enthalpy Method in Upwind Scheme

In this study, a numerical code with enthalpy method in upwind scheme is proposed to estimate the distribution of thermal stress in the molten pool, which is primarily determined by the type of the input power and travel speed of heating source. To predict the cracker deficit inside the workpiece, a simulated program satisfying the diagonal domination and Scarborough criterion provides a stable iteration. Meantime, an experimental performance, operated by robot arm 'DR-400' to provide a steady and continuous arc welding, was also conducted to verify the simulated result. By surveying the consistence of molten pool bounded by contrast shade and simulated melting contour on the surface of workpiece, the validity of model proposed to predict the thermal cracker has been successfully identified.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1974

Electron beam, laser beam and plasma arc welding studies

This program was undertaken as an initial step in establishing an evaluation framework which would permit a priori selection of advanced welding processes for specific applications. To this end, a direct comparison of laser beam, electron beam and arc welding of Ti-6Al-4V alloy was undertaken. Ti-6Al-4V was selected for use in view of its established welding characteristics and its importance in aerospace applications.

Banas, C. M.↗
NASA NTRS1985

Sensor control of robot arc welding

A basic problem in the application of robots for welding which is how to guide a torch along a weld seam using sensory information was studied. Improvement of the quality and consistency of certain Gas Tungsten Arc welds on the Space Shuttle Main Engine (SSME) that are too complex geometrically for conventional automation and therefore are done by hand was examined. The particular problems associated with space shuttle main egnine (SSME) manufacturing and weld-seam tracking with an emphasis on computer vision methods were analyzed. Special interface software for the MINC computr are developed which will allow it to be used both as a test system to check out the robot interface software and later as a development tool for further investigation of sensory systems to be incorporated in welding procedures.

Sias, F. R., Jr.↗
NASA NTRS1996

Mathematical Model Of Variable-Polarity Plasma Arc Welding

Mathematical model of variable-polarity plasma arc (VPPA) welding process developed for use in predicting characteristics of welds and thus serves as guide for selection of process parameters. Parameters include welding electric currents in, and durations of, straight and reverse polarities; rates of flow of plasma and shielding gases; and sizes and relative positions of welding electrode, welding orifice, and workpiece.

Hung, R. J.↗
DOE OSTI2024

Stress Relaxation Cracking in 347H Stainless Steel Arc Welds: Susceptibility Evaluation of Heat-Affected Zone

Stress relaxation cracking (SRC) is considered one of the major failure mechanisms for 347H stainless steel welds at elevated service temperatures or during post weld heat treatment (PWHT), especially within the heat-affected zone (HAZ). This work focuses on the characterization of SRC susceptibility within 347H physically simulated arc welded HAZ at elevated temperatures. A four-step SRC thermomechanical test in combination with finite element modeling (FEM) of the welding and testing processes is developed to establish a susceptibility map for HAZ. The test first runs a thermal cycle with three different peak temperatures (1335, 1275, and 1150 °C) to duplicate representative HAZ subzone microstructures, followed by time-to-failure examination under a variety of pre-stress (260–600 MPa) and pre-strain conditions (0.03–0.19) as a function of reheat temperatures between 750 and 1050 °C. With the aid of FEM, SRC susceptibility maps are generated to identify the threshold stress, plastic strain, and creep strain as a function of test temperature. It was found out that HAZ subzone with a lower peak temperature (1150 °C) appears to be slightly less susceptible to SRC than the other two subzones that experienced higher peak temperatures. Generally, time-to-fracture reduces with increasing initially applied stress and strain for all test temperatures. The pre-stress thresholds decrease from about 500 to 330 MPa as the testing temperature increases from 800 to 1050 °C, while the corresponding initial plastic strain thresholds reduces from 0.15 to 0.06. The SRC susceptibility was also evaluated through the Larson–Miller Parameter (LMP) analysis as a function of plastic strain, initial stress and starting stress upon reaching the testing temperature, respectively. The 1050 °C test with a high pre-applied strain (0.1) exhibits an extremely short time to failure (t = 3 s) that lies outside the general trend in LMP analysis. Additionally, it was identified that a plastic strain above 0.07 is identified to significantly reduce the bulk creep strain tolerance to fracture and therefore increases SRC susceptibility. Hardness measurement and fractography analysis indicated that the strain aging of niobium carbonitrides and other potential phases in conjunction with intergranular precipitates contributes to an increase in microhardness and increased intergranular cracking susceptibility.

14 SOLAR ENERGY↗
DOE OSTI2018

Strain and distortion monitoring during arc welding by 3D digital image correlation

A novel three-dimensional (3D) digital image correlation (DIC) approach using a stereovision system was developed to measure the evolution of strain and distortion near the fusion zone during the gas tungsten arc welding process. Unlike the previously reported two-dimensional (2D) DIC approach using a single camera, the 3D DIC method was immune to the out-of-plane displacement and was capable of measuring 3D deformation. Both 2D and 3D DIC approaches in welding applications were based on the utilisation of the novel high-temperature speckle and the pulsed laser illumination plus bandpass filters. However, the speckle pattern was partially specular reflective causing issues in subset matching in the 3D approach. A new algorithm and experimental procedure was incorporated to solve this problem.

47 OTHER INSTRUMENTATION↗
NASA NTRS1994

UAH mathematical model of the variable polarity plasma ARC welding system calculation

Significant advantages of Variable Polarity Plasma Arc (VPPA) welding process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. A mathematical model is presented to analyze the VPPA welding process. Results of the mathematical model were compared with the experimental observation accomplished by the GDI team.

Hung, R. J.↗
NASA NTRS1987

Examination of the physical processes associated with the keyhole region of variable polarity plasma arc welds in aluminum alloy 2219

The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. This study examined the effects of oxide, halide, and sulfate additions to the weld plate on the keyhole and the weld pool. Changes in both the arc plasma character and the bead morphology were correlated to the chemical environment of the weld. Pool behavior was observed by adding flow markers to actual VPPA welds. A low temperature analog to the welding process was developed. The results of the study indicate that oxygen, even at low partial pressures, can disrupt the stable keyhole and weld pool. The results also indicate that the Marangoni surface tension driven flows dominate the weld pool over the range of welding currents studied.

Walsh, Daniel W.↗
NASA NTRS1991

Heat sink effects in variable polarity plasma arc welding

The Space Shuttle External Tank is fabricated by the variable polarity plasma arc (VPPA) welding process. In VPPA welding, a noble gas, usually argon, is directed through an arc to emerge from the torch as a hot plasma jet. This jet is surrounded by a shielding gas, usually helium, to protect the weld from contamination with air. The high velocity, hot plasma jet completely penetrates the workpiece (resembling a line heat source) when operated in the 'keyhole' mode. The metal melts on touching the side of the jet, as the torch travels in the perpendicular direction to the direction of the jet, and melted metal moves around the plasma jet in the keyhole forming a puddle which solidifies behind the jet. Heat sink effects are observed when there are irregularities in the workpiece configuration, especially, if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, i.e., in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of this research is to study the effect of irregularities in workpiece configuration and fixture differences (heat sink effects) on the weld bead geometry with the ultimate objective to compensate for the heat sink effects and achieve a perfect weld. Experiments were performed on different workpiece geometries and compared to approximate models.

Abdelmessih, Amanie N.↗
NASA NTRS1983

The variable polarity plasma arc welding process: Its application to the Space Shuttle external tank

The technical history of the variable polarity plasma arc (VPPA) welding process being introduced as a partial replacement for the gas shielded tungsten arc process in assembly welding of the space shuttle external tank is described. Interim results of the weld strength qualification studies, and plans for further work on the implementation of the VPPA process are included.

Nunes, A. C., Jr.↗