Plasma electron beam development for welding applications.
Plasma electron beam for welding, deriving beam current from secondary emission by ion bombardment, discussing gas pressure, equipment and applications
Boring, K. L.↗
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Prediction and Measurement of X-Ray Spectral and Intensity Distributions from Low Energy Electron Impact Sources
In-vacuum electron beam welding is a technology that NASA considered as a joining technique for manufacture of space structures. The interaction of energetic electrons with metal produces x-rays. The radiation exposure to astronauts performing the in-vacuum electron beam welding must be characterized and minimized to insure safe operating conditions. This investigation characterized the x-ray environment due to operation of an in-vacuum electron beam welding tool. NASA, in a joint venture with the Russian Space Agency, was scheduled to perform a series of welding in space experiments on board the United States Space Shuttle. This series of experiments was named the International Space Welding Experiment (ISWE). The hardware associated with the ISWE was leased to NASA, by the Paton Welding Institute (PWI) in Ukraine, for ground based welding experiments in preparation for flight. Two tests were scheduled, using the ISWE electron beam welding tool, to characterize the radiation exposure to an astronaut during the operation of the ISWE. These radiation exposure tests consisted of Thermoluminescence Dosimeters (TLD's) shielded with material currently used by astronauts during Extra Vehicular Activities (EVA) and exposed to x-ray radiation generated by operation of an in-vacuum electron beam welding tool. This investigation was the first known application of TLD's to measure absorbed dose from x-rays of energy less than 10 KeV. The ISWE hardware was returned to Ukraine before the issue of adequate shielding for the astronauts was verified. Therefore, alternate experimental and analytical methods were developed to measure and predict the x-ray spectral and intensity distribution generated by electron impact with metal. These x-ray spectra were used to calculate the absorbed radiation dose to astronauts. These absorbed dose values were compared to TLD measurements obtained during actual operation of the in-vacuum electron beam welding tool. The calculated absorbed dose values were found to be in good agreement with the TLD values.
Edwards, David L.↗
Electron beam application to welding space propulsion components
Electron beam application to welding spacecraft propulsion components
ELECTRON BEAM WELDING↗
Absorbed Dose Determination Using Experimental and Analytical Predictions of X-Ray Spectra
Electron beam welding in a vacuum is a technology that NASA is investigating as a joining technique for manufacture of space structures. This investigation characterizes the x-ray environment due to operation of an in-vacuum electron beam welding tool and provides recommendations for adequate shielding for astronauts performing the in-vacuum electron beam welding. NASA, in a joint venture with the Russian Space Agency, was scheduled to perform a series of welding in space experiments on board the U.S. Space Shuttle. This series of experiments was named the international space welding experiment (ISWE). The hardware associated with the ISWE was leased to NASA by the Paton Welding Institute (PWI) in Ukraine for ground-based welding experiments in preparation for flight. Two ground tests were scheduled, using the ISWE electron beam welding tool, to characterize the radiation exposure to an astronaut during the operation of the ISWE. These radiation exposure tests used thermoluminescence dosimeters (TLD's) shielded with material currently used by astronauts during extravehicular activities to measure the radiation dose. The TLD's were exposed to x-ray radiation generated by operation of the ISWE in-vacuum electron beam welding tool. This investigation was the first known application of TLD's to measure absorbed dose from x rays of energy less than 10 keV. The ISWE hardware was returned to Ukraine before the issue of adequate shielding for the astronauts was completely verified. Therefore, alternate experimental and analytical methods were developed to measure and predict the x-ray spectral and intensity distribution generated by ISWE electron beam impact with metal. These x-ray spectra were normalized to an equivalent ISWE exposure, then used to calculate the absorbed radiation dose to astronauts. These absorbed dose values were compared to TLD measurements obtained during actual operation of the ISWE in-vacuum electron beam welding tool. The calculated absorbed dose values were found to be in agreement with the measured TLD values.
Edwards, D. L.↗
Technique Lowers Weld Power Requirements
Three electron-beam welds and a spacer are used to replace a single deep electron-beam weld. Technique would reduce power required for welding making it possible to use low-power sources.
Pessin, R.↗
Checking weld penetration
Fused wire in weld root area verifies weld penetration in electron-beam-welded joints. Method could be used in automotive, aircraft, and machinery manufacturing when electron-beam-welds cannot be inspected ultrasonically.
Macfarlane, D. I.↗
Laser Beam Welding for in-Space Joining Demonstrated Under Vacuum on the Ground and By Parabolic Flight Experiments
High energy density electron beam welding enabled the first and, to date, only American weld performed in space during the M551 experiment on Skylab in 1973. Though welding is critical to 90% of durable goods manufacturing in America, there is not yet regular and reliable application of welding processes to the In-space Servicing, Assembly, and Manufacturing (ISAM) sector. Fundamental studies are needed to develop basic capabilities and to enhance fundamental process knowledge, which will support follow-on efforts to mature in-space welding for use in commercial, defense, and other aerospace applications. The current work seeks to build on past flights and improve understanding and quantification of materials joining in space conditions using laser beam welding (LBW). LBW offers several advantages over the electron beam welding of Skylab, amongst others: reduced electromagnetic interference, less exposure of operators to ionizing radiation, and flexible delivery through optical fibers supporting unique workpieces and joints. Since there is no orbital laboratory to mature laser beam welding for space, the current effort addresses maturation of laser beam welding through parabolic flights augmented with data collection to enable numerical modeling efforts that capture the physical effects of the space environment. This team has retrofitted an LBW experimental apparatus that can simulate the vacuum and, during a parabolic flight, the reduced gravity & microgravity conditions of in-space welding. A team of Capstone students modified the setup, originally developed by NASA Langley Research Center for electron beam free-form fabrication, to replace its electron gun with a 1 kW, 1070 nm Yb fiber laser. The apparatus was further instrumented with temperature sensing and high-speed welding cameras to monitor and record changes in the thermal state of the workpiece, the melt pool, the laser penetration level, and the development and orientation of spatter & plumes. The system will operate autonomously, demonstrating its utility to uncrewed missions. During upcoming parabolic flight campaigns expected summer 2024, this LBW equipment will weld common aerospace alloys of aluminum, stainless steel, and titanium under conditions representative of the space environment. This data will guide future computational modeling efforts of laser welding in space and help to qualify in-space welding as a viable ISAM technique.
laser beam welding↗
Fatigue behavior of two alloys for Space Shuttle applications
Two superalloys used extensively in the Space Shuttle main engine are Incoloy 903 and Inconel 718. The fatigue behavior of the two alloys under varying conditions is considered. Three heats of Incoloy 903 and two of Inconel 718 were used in the study. Material was tested in several conditions, including mill polish, longitudinal mill polish, transverse mill polish, chemically milled, chemically milled plus shotpeened on one side and on both sides, gas tungsten arc welded, and electron beam welded. Both round and flat tensile specimens were tested in universal test machines. It was found that surface condition influences test results. Transverse scratches resulting from polishing and rougher surfaces lower the stress at runout in relation to that obtained on longitudinally polished and/or smooth-surfaced specimens.
Adsit, N. R.↗
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.↗
GRCop-84: A High-Temperature Copper Alloy for High-Heat-Flux Applications
GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) is a new high-temperature copper-based alloy. It possesses excellent high-temperature strength, creep resistance and low-cycle fatigue up to 700 C (1292 F) along with low thermal expansion and good conductivity. GRCop-84 can be processed and joined by a variety of methods such as extrusion, rolling, bending, stamping, brazing, friction stir welding, and electron beam welding. Considerable mechanical property data has been generated for as-produced material and following simulated braze cycles. The data shows that the alloy is extremely stable during thermal exposures. This paper reviews the major GRCop-84 mechanical and thermophysical properties and compares them to literature values for a variety of other high-temperature copper-based alloys.
Ellis, David L.↗
Welding investigation of a wrought FeMnAl steel for armor application
A new wrought FeMnAl steel contains high Mn content and high Al content. This steel has high strength. When it is compared to conventional steels with the similar strength, its density is lower. FeMnAl steels can be used in armor vehicle manufacturing, in which welding is a common practice to join the steel plates together. The welding of FeMnAl steels has not been sufficiently studied before. Here, this work studied the weldability and weld microstructure of an FeMnAl steel and provided useful data for the welding practice of FeMnAl steels. The influences of weld filler metals and shielding gases were studied, using single-pass bead-on-plate gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) two processes. The optimal filler metals and shielding gases have been determined to achieve the better weldability. Autogenous GTAW and electron beam welding were also conducted. Cracks were found in the HAZ in the GMAW welds and electron beam welds. Fewer or no cracks were found in the HAZ of GTAW welds. SEM, SEM/EDX, TEM, TEM/EDX, and EBSD were used to analyze the grain boundaries in the HAZ and the cracks. The grain boundaries of FeMnAl base metal are mostly high angle grain boundaries (HAGBs), which attract impurity and solute atoms and cause intergranular cracking. The proposed cracking mechanisms are liquation cracking and ductility-dip cracking. It was found that GTAW provides much better weldability for the FeMnAl steel than GMAW and EBW.
FeMnAl steel↗
Design of a welded joint for robotic, on-orbit assembly of space trusses
In the future, some spacecraft will be so large that they must be assembled on-orbit. These spacecraft will be used for such tasks as manned missions to Mars or used as orbiting platforms for monitoring the Earth or observing the universe. Some large spacecraft will probably consist of planar truss structures to which will be attached special purpose, self-contained modules. The modules will most likely be taken to orbit fully outfitted and ready for use in heavy-lift launch vehicles. The truss members will also similarly be taken to orbit, but most unassembled. The truss structures will need to be assembled robotically because of the high costs and risks of extra-vehicular activities. Some missions will involve very large loads. To date, very few structures of any kind have been constructed in space. Two relatively simple trusses were assembled in the Space Shuttle bay in late 1985. Here the development of a design of a welded joint for on-orbit, robotic truss assembly is described. Mechanical joints for this application have been considered previously. Welded joints have the advantage of allowing the truss members to carry fluids for active cooling or other purposes. In addition, welded joints can be made more efficient structurally than mechanical joints. Also, welded joints require little maintenance (will not shake loose), and have no slop which would cause the structure to shudder under load reversal. The disadvantages of welded joints are that a more sophisticated assembly robot is required, weld flaws may be difficult to detect on-orbit, the welding process is hazardous, and welding introduces contamination to the environment. In addition, welded joints provide less structural damping than do mechanical joints. Welding on-orbit was first investigated aboard a Soyuz-6 mission in 1969 and then during a Skylab electron beam welding experiment in 1973. A hand held electron beam welding apparatus is currently being prepared for use on the MIR space station. Presently, Marshall Space Flight Center is evaluating processes appropriate for on-orbit welding. A low gravity environment has been found to have very minor effects on the welding processes appropriate for this application. This is based on tests run on-orbit as well as low gravity environments achieved by flying aircraft in parabolic trajectories. It appears that a modified form of gas tungsten arc welding (GTAW) will be most appropriate for welding together structures on-oribt. The process has been modified to work in a vacuum by providing gas to the arc zone by means of a hollow tungsten electrode with special shielding. A commercial tube welding head has been successfully modified for use on-orbit with a gas leakage rate of approximately 2.5 liters/min. To develop as realistic a joint as possible, a specific truss structure was selected on which to base the design. The structure considered was based on the 120 foot diameter aerobrake tetrahedral truss structure. The truss members were assumed to consist of graphite/epoxy tubes. Also, it was assumed that the nodes were constructed of 2219-T87 aluminum alloy. The magnitude of the member load assumed for design purposes was 100 kips.
Rule, William K.↗
Non-circular electron beam spot welds in stainless steel alloys
Circularly symmetric-shaped spot welds are desirable for welding applications as they relate to heat and fluid flow conditions in the melt pool with predictable weld penetrations and repeatable results. Non-circular spot welds on the other hand result in undesirable and unpredictable weld penetrations or non-bridging of the liquid melt pool across the joint. Two known causes for non-circular melt pools occur when welding dissimilar metals, or when welding with skewed electron or laser beams that are not perpendicular to the surface. A largely unexplored additional factor, shown here, is an asymmetric power density distribution within the beam that can create non-circular melt pools even though the beam dimensions are much smaller than the melt pool itself.
36 MATERIALS SCIENCE↗
Evaluation of Rhenium Joining Methods
Coupons of rhenium-to-Cl03 flat plate joints, formed by explosive and diffusion bonding, were evaluated in a series of shear tests. Shear testing was conducted on as-received, thermally-cycled (100 cycles, from 21 to 1100 C), and thermally-aged (3 and 6 hrs at 1100 C) joint coupons. Shear tests were also conducted on joint coupons with rhenium and/or Cl03 electron beam welded tabs to simulate the joint's incorporation into a structure. Ultimate shear strength was used as a figure of merit to assess the effects of the thermal treatment and the electron beam welding of tabs on the joint coupons. All of the coupons survived thermal testing intact and without any visible degradation. Two different lots of as-received, explosively-bonded joint coupons had ultimate shear strengths of 281 and 310 MPa and 162 and 223 MPa, respectively. As-received, diffusion-bonded coupons had ultimate shear strengths of 199 and 348 MPa. For the most part, the thermally-treated and rhenium weld tab coupons had shear strengths slightly reduced or within the range of the as-received values. Coupons with Cl03 weld tabs experienced a significant reduction in shear strength. The degradation of strength appeared to be the result of a poor heat sink provided during the electron beam welding. The Cl03 base material could not dissipate heat as effectively as rhenium, leading to the formation of a brittle rhenium-niobium intermetallic.
Reed, Brian D.↗
Computational and Physics-Based Modeling for the Development of in-Space Welding Technology
Welding will be an enabling technology for in-space assembly and manufacturing (ISAM) and in-space repair operations in support of the growing Space Economy. Prospective use cases of welding include metal repair on long-duration lunar surface missions and assembly of large structures that exceed dimensions of the currently available launch vehicle envelopes such as space arrays, tall lunar transmission towers, or even large transit vehicles powered by nuclear propulsion. There is a brief history of beam welding for in-space use. Soviet and NASA astronauts performed electron beam welds (EBW) in space in the late-1960s through mid-1980s and several parabolic flights of laser beam welding (LBW) were undertaken in the USA and Canada in the early-1990s. Work has since stagnated until the recent boom of the in-space economy has demonstrated need for continued development of EBW and LBW processes, which are desirable for their compactness, low mass, low power consumption, and high wall plug efficiency. No space-based manufacturing laboratory capable of demonstrating, developing, and applying welding processes exists, and costs are high to develop and fly individual space-based trials. This drives the current approach to develop welding technology with computational and physics-based models in tandem with earth-based experiments. Several approaches are taken to complement and drive the selection of instrumentation for planned parabolic and suborbital flights. First, a thermal model of Skylab EBW experiments is established and compared to empirical data. Next, the model is used to show variation between Earth-based and in-space weld structure and properties through exploration of key variables that define the Low earth orbit and lunar surface space environments, namely temperature (40 – 400 K), pressure (10-10 to 104 Pa), and gravity (10-6 g to 1 g). Finally, physical processes associated with heat and mass transport during welding are evaluated through several case studies across the above variable ranges demonstrating need for further research.
in-space welding↗
A determination of the current density in electron beams
Current gathering rotating probe techniques were used to examine the envelope shape and power density profile of electron beams used in electron beam welding devices. The electron power density contours which determine the shape of the weld vapor cavity, penetration, and local heat distribution were considered. A mathematical analysis consistent with a rotating probe technique necessary to determine the current density distribution (assumed symmetrically radial) in a cross-section of the beam is provided. An explanation of the experimental technique for obtaining data, a BASIC language computer program to determine the current density from the data, and a study indicating the level of confidence to be associated with results obtained are also provided. An example of the application of the analysis to some experimental electron beam data is included.
Beil, R. J.↗
Dovetail Rotor Construction For Permanent-Magnet Motors
New way of mounting magnets in permanent-magnet, electronically commutated, brushless dc motors. Magnets wedge shaped, tapering toward center of rotor. Oppositely tapered pole pieces, electron-beam welded to rotor hub, retain magnets against centrifugal force generated by spinning rotor. To avoid excessively long electron-beam welds, pole pieces assembled in segments rather than single long bars.
Kintz, Lawrence J., Jr.↗
Experimental studies of a high-gradient X-band welded hard-copper split accelerating structure
We report on recent research on high-gradient radio frequency (RF) accelerating structures indicates that the use of hard copper alloys provides improvement in high gradient performance over annealed copper. Such structures are made by bonding individually manufactured parts. However, there are no well-established bonding techniques that preserve the hardness, surface finish and cleanliness required for high gradient operation. To preserve the copper hardness, RadiaBeam has developed a novel high-gradient split accelerating structure, based on electron beam welding joining technique. This technique provides efficient bonding with strong, clean welds and minimal thermal loading, while maintaining a clean inner RF environment. Our RF design and fabrication methodology limits the small heat affected zone to the outer cavity envelop, with virtually no distortions or thermal loading of critical RF surfaces. It also incorporates provisions to precisely control the gap despite conventional issues with weld joint shrinkage. To date we have manufactured and validated an RF accelerating structure joined by electron-beam welding that incorporates a novel open split design to significantly reduce the assembly complexity and cost. In this paper, we will present the electromagnetic design of this structure, discuss bonding, and present the results of high-power tests, where the accelerating gradients of 140 MV m -1 with surface peak fields of 400 MV m -1 were achieved for flat-top pulse length of 600 ns with an RF breakdown rate of 10 -4 1/(pulsecm).
43 PARTICLE ACCELERATORS↗