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At least 91 records · Page 5

Separating Images For Welding Control

Torch for automatic gas/tungsten-arc welding provides separate coaxial views of weld to two sensors. Each sensor functions in real time without interfering with other. One sensor provides information for vision-guided seam tracker; other feeds data to an optical weld-contour monitor for control penetration. Contains beam splitter at angle of 45 degree with electrode axis. Beam splitter reflects wavelengths below 550 nm to sensor for seam tracking. Transmits wavelengths above 550 nm to sensor for weld-contour monitoring. Filters added to split beam paths to limit further spectra transmitted to sensors. Beam splitter and filters easily changed to suit material and welding parameters.

Gordon, Stephen S.↗

Detecting overpenetration of electron-beam welds

Gold plate beneath weldment reveals areas of excess penetration during X-ray inspection. Technique is applicable to critical electron-beam welds, such as those in gas turbines and pressure vessels.

Macfarlane, D. I.↗

Enhancement Of Penetrant-Inspection Images

Proposed computerized video system processes images of fluorescent dyes absorbed in flaws in welds. Video camera, held by operator or by remote manipulator, views weld illuminated by visible white and ultraviolet light. Images of penetrating dye in cracks and voids in weld joint appear on video monitor. Fluorescent features enhanced by software to facilitate identification of true flaws and record important data.

Wilson, Rhonda C.↗

Closed-Loop Control System for Friction Stir Welding Retractable Pin Tool

NASA invention disclosure, NASA Case No. MFS-31413, entitled "System for Controlling the Stirring Pin of a Friction Stir Welding Apparatus", (Patent Pending) authored by Jeff Ding, Dr Peter Romine and Pete Oelgoetz, addresses the precision control of the friction stir welding process. The closed-loop control system automatically adjusts the spinning welding pin, real-time, to maintain a precise penetration ligament (i.e., distance between pin-tip and weld panel backside surface). A specific pin length can be maintained while welding constant thickness or tapered material thickness weld panels. The closed-loop control system provides operator data and information relative to the exact position of the welding pin inside the weld joint. This paper presents the closed-loop RPT control system that operates using the auto-feedback of force signals sensed by the tip and shoulder of the welding pin. Significance: The FSW process can be successfully used in a production environment only if there is a method or technique that informs the FSW operator the precise location of the welding pin inside the weld joint. This is essential for applications in aerospace, automotive, pressure vessel, commercial aircraft and other industries.

Ding, R. Jeffrey↗

Laser welding in space

Autogenous welds in 304 stainless steel were performed by Nd-YAG laser heating in a simulated space environment. Simulation consists of welding on the NASA KC-135 aircraft to produce the microgravity and by containing the specimen in a vacuum chamber. Experimental results show that the microgravity welds are stronger, harder in the fusion zone, have deeper penetration and have a rougher surface rippling of the weld pool than one-g welds. To perform laser welding in space, a solar-pumped laser concept that significantly increases the laser conversion efficiency and makes welding viable despite the limited power availability of spacecraft is proposed.

Kaukler, W. F.↗

Fatigue behavior of 5Ni-Cr-Mo-V steel weldments containing fabrication discontinuities

The applicability of linear elastic fracture mechanics to characterize the fatigue behavior of high-strength steel weldments containing lack-of-penetration (LOP) and slag/lack-of-fusion (S/LOF) discontinuities is explored. Full penetration, double-V butt welds with reinforcements removed were tested under zero-to-tension axial loading. Various filler metals and welding techniques were used. Both sound welds and welds containing discontinuities were cycled to failure. Where possible, cycles to crack initiation were estimated by strain gage measurements. The fracture mechanics approach was successful in correlating the fatigue lifetimes of specimens containing single LOP discontinuities of varying size. However, the fatigue behavior of specimens containing multiple S/LOF discontinuities proved to be much more complex and difficult to analyze.

Gill, Steven J.↗

Magnetically-Guided Penetrant Applicator

Small wheeled vehicle moved inside nonmagnetic enclosure. Miniature magnetically guided truck uses foam-rubber sponge pads to apply penetrant fluid for inspection of welds in hidden surfaces of nonmagnetic tubes. Risk of explosion less than if electric motor used to drive vehicle. Inexpensive to make and made in range of sizes.

Molina, Orlando G.↗

Laser welding in a reduced gravity environment

Preliminary results on the effects of reduced gravity on laser welding of stainless steel and other materials are reported. Laser welding experiments using a low power (10-18 watts) Nd-YAG laser have been performed on the NASA KC-135, which flies parabolic maneuvers to simulate reduced gravity conditions. Experiments on 0.005-0.010 inch thick stainless steel samples displayed a pronounced change in weld bead width, depth of penetration and surface ripple with changes in gravity level.

Workman, Gary L.↗

The feasibility of producing aluminum-lithium structures for cryogenic tankage applications by laser beam welding

Aluminum-lithium alloys exhibit high strength, high elastic modulus, and low density as well as excellent cryogenic mechanical properties making them ideal material candidates for cryogenic tanks. NASA has proposed the use of 'built-up' structure for panels fabricated into cryogenic tanks replacing current conventional machining. Superplastically formed stiffeners would be joined to sheet (tank skin) that had been roll formed to the radius of the tank in order to produce panels. Aluminum-lithium alloys of interest for producing the built-up structure include alloy 2095-T6 stiffeners to 2095-T8 sheet and alloy 8090-T6 stiffeners to 2090-T83 sheet. Laser welding, with comparable joint properties, offers the following advantages over conventional welding: higher production rates, minimal degradation within the heat affected zones, and full process automation. This study established process parameters for laser beam welding, mechanical property determinations, metallographic characterization, and fabrication of prototype panels. Tensile tests representing partial penetration of the skin alloys provided joint efficiencies between 65 and 77 percent, depending upon alloy and degree of penetration. Results of tension shear tests of lap welds indicated that the combination of 2095-T6 to 2090-T8 exhibited significantly higher weld shear strength at the interface in comparison to welds of 8090-T6 to 2090-T83. The increased shear strength associated with 2095 is believed to be due to the alloy's ability to precipitation strengthening (naturally age) after welding.

Martukanitz, R. P.↗

Keyhole and weld shapes for plasma arc welding under normal and zero gravity

A first order study of the interfacial (keyhole) shape between a penetrating argon plasma arc jet and a stationary liquid metal weld pool is presented. The interface is determined using the Young-Laplace equation by assuming that the plasma jet behaves as a one-dimensional ideal gas flow and by neglecting flow within the weld pool. The solution for the keyhole shape allows an approximate determination of the liquid-solid metal phase boundary location based on the assumption that the liquid melt is a stagnant thermal boundary layer. Parametric studies examine the effect of plasma mass flow rate, initial plasma enthalpy, liquid metal surface tension, and jet shear on weldment shape under both normal and zero gravity. Among the more important findings of this study is that keyhole and weld geometries are minimally affected by gravity, suggesting that data gathered under gravity can be used in planning in-space welding.

Keanini, R. G.↗

How an Electron Beam (Eventually) Penetrates Ceramic Cloth

In anticipation of the International Space Welding Experiment (ISWE) the effect of an electron beam was investigated on Nextel AF-62 ceramic cloth designed to withstand temperatures up to 1427 C. It was anticipated that the cloth would take a static charge that would repel the beam and remain undamaged. It was found that after some seconds the impinging beam penetrated penetrated the cloth. Further, the penetration time went up significantly both at longer and at closer standoff distances. A tentative explanation appears to fit the observed facts. The electrons in the beam generate positive ions by collisions with the contaminant gas molecules in the vacuum chamber. The positive ions transfer a small but significant fraction of the beam power to the cloth. Under the impingement of the positive ions the cloth heats up until sufficient outgassing occurs to initiate arcing. Once arcing occurs the full beam power impinges on the cloth and, almost instantaneously, burns a hole.

Nunes, A. C., Jr.↗

Microwave Tissue Soldering for Immediate Wound Closure

A novel approach for the immediate sealing of traumatic wounds is under development. A portable microwave generator and handheld antenna are used to seal wounds, binding the edges of the wound together using a biodegradable protein sealant or solder. This method could be used for repairing wounds in emergency settings, by restoring the wound surface to its original strength within minutes. This technique could also be utilized for surgical purposes involving solid visceral organs (i.e., liver, spleen, and kidney) that currently do not respond well to ordinary surgical procedures. A miniaturized microwave generator and a handheld antenna are used to deliver microwave energy to the protein solder, which is applied to the wound. The antenna can be of several alternative designs optimized for placement either in contact with or proximity to the protein solder covering the wound. In either case, optimization of the design includes the matching of impedances to maximize the energy delivered to the protein solder and wound at a chosen frequency. For certain applications, an antenna could be designed that would emit power only when it is in direct contact with the wound. The optimum frequency or frequencies for a specific application would depend on the required depth of penetration of the microwave energy. In fact, a computational simulation for each specific application could be performed, which would then match the characteristics of the antenna with the protein solder and tissue to best effect wound closure. An additional area of interest with potential benefit that remains to be validated is whether microwave energy can effectively kill bacteria in and around the wound. Thus, this may be an efficient method for simultaneously sterilizing and closing wounds. Using microwave energy to seal wounds has a number of advantages over lasers, which are currently in experimental use in some hospitals. Laser tissue welding is unsuitable for emergency use because its large, bulky equipment cannot be easily moved between operating rooms, let alone relocated to field sites where emergencies often occur. In addition, this approach is highly dependent on the uniformity and thickness of the protein solder as well as the surgeon s skills. In contrast, the use of microwave energy is highly tolerant of the thickness of the protein solder, level of fluids in and around the wound, and other parameters that can adversely affect the outcome of laser welding. However, controlling the depth of penetration of the microwave energy into the wound is critical for achieving effective wound sealing without damaging the adjacent tissue. In addition, microspheres that encapsulate metallic cores could also be incorporated into the protein solder to further control the depth of penetration of the microwave energy.

Arndt, G. Dickey↗

Chamber free fusion welding root side purging method and apparatus

A method and apparati are presented for non-chamber root side purging in fusion welding of oxygen reactive metals which require that the molten weld zone and local solid areas of the weld seam remaining at high temperatures be shielded from normal atmosphere to prevent degradation of the welded area. The apparati provide an inert atmosphere to the root side of a weld joint through a porous medium whereby the jet-like thrust of the plasma arc actually draws the continuously supplied inert atmosphere into the path of the molten or high temperature solid weld zone. The porous medium is configured so it can be placed at the borders of the weld seam and substantially parallel to the seam without restricting the view of the root side of the seam. The inert gas is dispersed evenly through the porous media and across the weld seam, at the point of arc penetration and in front of and behind the arc. The apparati can be constructed so as to limit the amount of inert gas flow and can be mobile and travel synchronously with the welding arc.

Mcgee, William F.↗

Chamber free fusion welding root side purging method and apparatus

A method and apparati are presented for non-chamber root side purging in fusion welding of oxygen reactive metals which require that the molten weld zone and local solid areas of the weld seam remaining at high temperatures be shielded from normal atmosphere to prevent degradation of the welded area. The apparati provide an inert atmosphere to the root side of a weld joint through a porous medium whereby the jet-like thrust of the plasma arc actually draws the continuously supplied inert atmosphere into the path of the molten or high temperature solid weld zone. The porous medium is configured so it can be placed at the borders of the weld seam and substantially parallel to the seam without restricting the view of the root side of the seam. The inert gas is dispersed evenly through the porous media and across the weld seam, at the point of arc penetration and in front of and behind the arc. The apparati can be constructed so as to limit the amount of inert gas flow and can be mobile and travel synchronously with the welding arc.

Dailey, J. R.↗

Shear strength of aluminum fillet welds

Shear-strength tests on aluminum fillet welds are documented in report. Test were made on aluminum alloy 2219 to aid designers in specifying sizes and lengths of fillet welds necessary to sustain expected loads in this material. Report discusses fillet-weld size and geometry, including root penetration and surface contour.

Lovoy, C. V.↗

Detection of lack of fusion using opaque additives, phase 1

Two major problems in welded aluminum spacecraft structure, reliable nondestructive inspection for incomplete weldment penetration and the rapid oxidation of aluminum surfaces left exposed to the atmosphere are investigated. The approach employed to solve both problems was to employ copper as a coating to prevent oxidation of the aluminum and as an opaque additive in the weldment to enhance X-ray detection in the event of incomplete penetration. Both plasma spray and vacuum vapor deposition techniques were evaluated for depositing the copper. A series of welded panels was made using three thicknesses of vacuum-vapor-deposited copper. All weldments were nondestructively inspected by X-ray, then excised into tensile and bend specimens. Mechanical tests were conducted and all data evaluated. It was determined that the vacuum-vapor-deposited coating was superior to a plasma sprayed coating of the same thickness. The vacuum-vapor-deposited coating was more uniform in thickness, provided complete coverage of the aluminum, and was free of cracks and porosity.

Cook, J. L.↗

System for Controlling the Stirring Pin of a Friction Stir Welding Apparatus

A control is provided for a friction stir welding apparatus comprising a pin tool which includes a shoulder and a rotating pin extending outwardly from the shoulder of the pin tool and which, in use, is plunged into a workpiece formed contacting workpiece members to stir weld the members together. The control system controls the penetration of the pin tool into the workpiece members which are mounted on a support anvil. The control system includes a pin length controller for controlling pin length relative to the shoulder and for producing a corresponding pin length signal. A pin force sensor senses the force being exerted on the pin during welding and produces a corresponding actual pin force signal. A probe controller controls a probe extending outwardly from the pin, senses a parameter related to the distance between the probe and the supporting anvil and produces a corresponding probe signal. A workpiece standoff sensor senses the standoff distance between the workpiece and the standoff sensor and produces a corresponding standoff signal. A control unit receives the various signals, together with a weld schedule, and, based on these signals and the weld schedule, controls the pin length controller so as to control pin penetration into the workpiece.

Ding, R. Jeffrey↗

Nuclear Plant Inspection

Engineers from the Power Authority of the State of New York use a Crack Growth Analysis Program supplied by COSMIC (Computer Software Management and Information Center) in one stage of nuclear plant inspection. Welds of the nuclear steam supply system are checked for cracks; radiographs, dye penetration and visual inspections are performed to locate cracks in the metal structure and welds. The software package includes three separate crack growth analysis models and enables necessary repairs to be planned before serious problems develop.

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