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Preweld calibration check helps to ensure welding torch on computer-controlled welding robot mounted properly, right gas cup selected, and length of extension of electrode adjusted correctly. Performed by operator just before dry run for each set of parts welded. Procedure takes 2 to 3 minutes and enables correction of errors before parts or equipment damaged.
Orbital welding head positioned by robot controls motion and voltage of arc-welding torch mounted in head. New head encircles part at torch end, and held and manipulated by robot arm at opposite end. Entire welding operation automated. Useful for operations in hazardous environments.
Inconel 718 weldments were repaired 3, 6, 9, and 13 times using the gas tungsten arc welding process. The welded panels were machined into mechanical test specimens, postweld heat treated, and nondestructively tested. Tensile properties and high cycle fatigue life were evaluated and the results compared to unrepaired weld properties. Mechanical property data were analyzed using the statistical methods of difference in means for tensile properties and difference in log means and Weibull analysis for high cycle fatigue properties. Statistical analysis performed on the data did not show a significant decrease in tensile or high cycle fatigue properties due to the repeated repairs. Some degradation was observed in all properties, however, it was minimal.
The objective was to assist the EH 42 Division in putting together a vacuum system that could attain the desired pressure and be large enough to accommodate the gas-metal arc (GMA) welding fixture apparatus. A major accomplishment was the design and fabrication of the controller/annunciator for the 4' by 8' system. It contains many safety features such as thermocouple set point relays that will only allow inlet and exit gas and vacuum valves to be operated at pre-selected system pressures, and a fail safe mode for power interruptions and operator mistakes. It is felt that significant progress was made in this research effort to weld in a vacuum environment. With continued efforts to increase the pump speeds for vacuum chambers and further studies on weld fixtures and gas inlet pressures, the NASA program will be successful.
The objective of this paper is to demonstrate how welding practice and joint design affect the performance of the joint. Also demonstrated is the importance of weld inspection to ensure quality welds.
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.
In faster, easier technique, material in weld zone fictitiously softened to negligibly low modulus of elasticity, and material considered deformed to specified offset. Displacements caused by deformation computed by analysis of static stresses and strains in fictitiously deformed material, using specified offset as displacement boundary condition. Resulting displacements added to coordinates of corresponding nodes of original (nonoffset) mathematical model of welded part. Technique used to modify large finite-element mathematical model to any desired weld offset configuration in short time.
Process derived from arc welding produces films of high quality. Modified gas/tungsten-arc welding process developed for use in outer space. Welding apparatus in process includes hollow tungsten electrode through which inert gas flows so arc struck between electrode and workpiece in vacuum of space. Offers advantages of fast deposition, possibility of applying directional impetus to flow of materials, very low pressure at surface being coated, and inert environment.
Programming artifice keeps weld puddle from running off. Dummy points added during off-line programming of circular, noncontiguous computer-controlled weld path to keep weld puddle in proper orientation at ends of path. Incorporation of dummy points simple and requires only few extra minutes of programming effort.
Report presents results of empirical evaluation of theorectical equation that predicts ultimate tensile strength of butt weld as function of some properties of welded metal and of geometry of weld.
A preliminary design for a weldable truss joint for on-orbit assembly of large space structures is described. The joint was designed for ease of assembly, for structural efficiency, and to allow passage of fluid (for active cooling or other purposes) along the member through the joint. The truss members were assumed to consist of graphite/epoxy tubes to which were bonded 2219-T87 aluminum alloy end fittings for welding on-orbit to truss nodes of the same alloy. A modified form of gas tungsten arc welding was assumed to be the welding process. The joint was designed to withstand the thermal and structural loading associated with a 120-ft diameter tetrahedral truss intended as an aerobrake for a mission to Mars.
In June 1991 work was initiated at MSFC on an end-effector for 'Robotic Assembly of Welded Truss Structures in Space'. The case for welded joint assembly on orbit was discussed in the 1991 SFFP Final Report 'D'. Data drawn from Aerobrake studies (supported by the ISAAC program) allowed the more detailed investigations that accompany a design with relatively concrete goals. This principle guides current efforts to develop scenarios that further demonstrate the utility of welding for space construction and/or repair.
The instrument described in this manual was developed at the University of Texas at El Paso under contract from the National Aeronautics and Space Administration Marshall Space Flight Center. The instrument has been used to detect hydrogen in the shielding gas of Variable Polarity Plasma Arc (VPPA) welds at concentrations of less than 100 ppm. The instrument makes measurements in real time during the welding operation and provides the operator with an easily readable graphic display of the present level of hydrogen in the arc as well as the level of hydrogen over the past approximately five minutes. In this way the welder can not only tell if the present level of hydrogen is excessive, but can see what changes in weld parameters have done to the level of hydrogen. The welder can set the level of hydrogen that is considered critical and the instrument display will indicate when that level has been exceeded. All detection is from the torch side. All needed equipment is supplied by the developer except for an IBM PC compatible computer which must be supplied by the user. Source code is supplied in this manual so that the user can modify the control program as desired.
The object of this investigation is to make available to the aircraft industry authoritative information on the strength, weight, and cost of a number of types of welded joints. This information will, also, assist the aeronautics branch in its work of licensing planes by providing data from which the strength of a given joint may be estimated. As very little material on the strength of aircraft welds has been published, it is believed that such tests made by a disinterested governmental laboratory should be of considerable value to the aircraft industry. Forty joints were welded under procedure specifications and tested to determine their strengths. The weight and time required to fabricate were also measured for each joint.
The discussion in this article refers to gas welding of thin-walled parts of up to about 3 mm thickness. It was proven that by restricting the sulphur, carbon, and phosphorous content, and by electric-furnace production of the steel, it was possible in a short time to remove this defect. Weld hardness - i.e., martensite formation and hardness of the overheated zone - has no connection with the tendency to weld-crack development. Si, Cr, Mo, or V content has no appreciable effect, while increased manganese content tends to reduce the crack susceptibility.
Artificial neural networks considered for use in monitoring and controlling gas/tungsten arc-welding processes. Relatively simple network, using 4 welding equipment parameters as inputs, estimates 2 critical weld-bead paramaters within 5 percent. Advantage is computational efficiency.
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.
The weldability of W-Cu composite sheet was investigated using simulated and welded joints. The welded joints were produced in a vacuum hot press. Tensile test results showed that simulated joints can provide strength and failure mode data which can be used in joint design for actual weldments. Although all of the welded joints had flaws, a number of these joints were as strong as the W-Cu composite base material.