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Simple device promotes defect-free welds in oxidation-prone metals. Welding torch pulls trailing shield behind to provide protective shield of argon gas over hot weld bead. Guide at front of torch holder feeds welding wire to joint. Shield bent or straightened to fit closely against weld joint.
A generalized method for controlling a six degree-of-freedom (DOF) robot and a two DOF positioner used for arc welding operations is described. The welding path is defined in the part reference frame, and robot/positioner joint angles of the equivalent eight DOF serial linkage are determined via an iterative solution. Three algorithms are presented: the first solution controls motion of the eight DOF mechanism such that proper torch motion is achieved while minimizing the sum-of-squares of joint displacements; the second algorithm adds two constraint equations to achieve torch control while maintaining part orientation so that welding occurs in the downhand position; and the third algorithm adds the ability to control the proper orientation of a wire feed mechanism used in gas tungsten arc (GTA) welding operations. A verification of these algorithms is given using ROBOSIM, a NASA developed computer graphic simulation software package design for robot systems development.
The use and benefits of automated variable polarity plasma arc (VPPA) welding of Al joints are described. The entire welding system, including welding head manipulator, weld-wire feed, torch, and power supply are computer controlled. The importance of proper torch dynamics and the control of argon gas flow through the plasma orifice are discussed. The use of arc-voltage control, the improvements in system monitoring, and the reduction or elimination of electromagnetic interferences are examined. VPPA welding is applicable to joining Space Shuttle components, and an example of its use on an External Tank of the Shuttle is presented.
Optical system for coaxial-viewing welding torch enables perception or measurement of depth. Light from welding area passes through beam splitter into two optical trains forming two images, each viewed along line making small angle with axis of torch. Two lines of sight intersect at weld pool. Parallax between two views provides sensation of depth over entire field view.
Conical, stainless-steel mirror attached to end of welding torch improves distribution of light on work-piece as welding monitored through torch by television. Television monitoring protects operators from intense arc light and facilitates automated welding. Simple, small, and easy to install and remove, mirror relatively nonintrusive.
Tool aids in alignment of oscillator probe on variable-polarity plasma-arc welding torch. Probe magnetically pulls arc from side to side as it moves along joint. Tensile strength of joint depends on alignment of weld bead and on alignment of probe. Operator installs new tool on front of torch body, levels it with built-in bubble glass, inserts probe in slot on tool, and locks probe in place. Procedure faster and easier and resulting alignment more accurate and repeatable.
Arc-light reflector for through-the-torch welding vision system designed expressly for use in welding ducts of small diameter. Cylindrical reflector positioned to reflect light diffusely from welding arc onto nearby surface of workpiece for most advantageous viewing along axis of welding torch.
A welding torch for gas tungsten arc welding apparatus has a hollow tungsten electrode including a ceramic liner and forms the filler metal wire guide. The wire is fed through the tungsten electrode thereby reducing the size of the torch to eliminate clearance problems which exist with external wire guides. Since the wire is preheated from the tungsten more wire may be fed into the weld puddle, and the wire will not oxidize because it is always within the shielding gas.
Optical welding sensors replaced without realignment. Mounting fixture for optical weld-penetration sensor enables accurate and repeatable alignment. Simple and easy to use. Assembled on welding torch, it holds sensor securely and keeps it pointed toward weld pool. Designed for use on gas/tungsten arc-welding torch, fixture replaces multipiece bracket.
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.
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.
The need for automated plasma welding was identified in the early stages of the Space Station Freedom Program (SSFP) because it requires approximately 1.3 miles of welding for assembly. As a result of the Variable Polarity Plasma Arc Welding (VPPAW) process's ability to make virtually defect-free welds in aluminum, it was chosen to fulfill the welding needs. Space Station Freedom will be constructed of 2219 aluminum utilizing the computer controlled VPPAW process. The 'Node Radial Docking Port', with it's saddle shaped weld path, has a constantly changing surface angle over 360 deg of the 282 inch weld. The automated robotic VPPAW process requires eight-axes of motion (six-axes of robot and two-axes of positioner movement). The robot control system is programmed to maintain Torch Center Point (TCP) orientation perpendicular to the part while the part positioner is tilted and rotated to maintain the vertical up orientation as required by the VPPAW process. The combined speed of the robot and the positioner are integrated to maintain a constant speed between the part and the torch. A laser-based vision sensor system has also been integrated to track the seam and map the surface of the profile during welding.
An investigation was conducted in an altitude test chamber at the NACA Lewis Laboratory to determine the altitude starting characteristics of an afterburner with autoignition and with hot-streak ignition. Transient afterburner ignition data were obtained over a range of altitudes from 30,000 to 50,000 feet at a flight Mach number of 0.60. Afterburner ignition with a torch igniter located axially at approximately the midpoint of the combustion chamber was possible over the entire range, but ignition ignition with a torch igniter located in the transition section 1 5/8 inches upstream of the turbine stators proved unsatisfactory at an altitude of 50,000 feet due to the inability to obtain flame through the turbine. Increasing the afterburner-inlet total pressure at a constant afterburner fuel-air ratio decreased the afterburner ignition time. Hot-streak ignition was possible within 2 seconds after the time required to obtain the preset, normal afterburner fuel pressure, whereas autoignition required 4 to 7 seconds for the range of altitudes investigated. Following the ignition there was a period of oscillatory operation existing in the engine-afterburner before steady-state operation was attained. The time required for steady-state stable operation decreased as afterburner inlet total pressure increased. The duration of oscillations also decreased with hot-streak ignition because the fuel-air mixture was ignited before a large volume of combustible mixture was accumulated in the afterburner.
Proposed optical system integrated into plasma arc welding torch provides image of leading edge of weld pool and welding-arc-initiation point. Welding torch aligned better with joint. System includes coherent bundle of optical fibers and transparent cup.
A welding torch for plasma arc welding apparatus has a transparent shield cup disposed about the constricting nozzle, the cup including a small outwardly extending polished lip. A guide tube extends externally of the torch and has a free end adjacent to the lip. First and second optical fiber bundle assemblies are supported within the guide tube. Light from a strobe light is transmitted along one of the assemblies to the free end and through the lip onto the weld site. A lens is positioned in the guide tube adjacent to the second assembly and focuses images of the weld site onto the end of the fiber bundle of the second assembly and these images are transmitted along the second assembly to a video camera so that the weld site may be viewed continuously for monitoring the welding process.
This report describes progress on the first year of a research program on the infrared radiation of air plasmas conducted in the High Temperature Gasdynamics Laboratory at Stanford University. This program is intended to investigate the masking of infrared signatures by the air plasma formed behind the bow shock of high velocity missiles. To this date, the radiative emission of air plasmas in the infrared has been the object of few experimental investigations, and although several infrared systems are already modeled in radiation codes such as NEQAIR, measurements are required to validate numerical predictions and indicate whether all transitions of importance are accounted for. The present program is motivated by the fact that 9 excited states (A, B, C, D, B', F, H, and H') of NO radiate in the infrared, especially between 1 and 1.5 microns where at least 9 transitions involving can be observed. Because these IR transitions are relatively well separated from each other, excited NO states concentrations can be easily measured, thus providing essential information on excited-state chemistry for use in optical diagnostics or in electronic excitation model validation. Developing accurate collisional-radiative models for these excited NO states is of importance as the UV-VUV transitions of NO (beta, gamma, epsilon, beta prime, gamma prime) produce a major, if not dominant, fraction of the radiation emitted by air plasmas. During the first year of the program, research has focused on the spectral range 1.0 to 1.5 microns, as detailed in Section 2 of this report. The measurements, conducted in a 50 kW radio-frequency inductively coupled plasma torch operating on air at atmospheric pressure, extend previous shock tube investigations by Wray to a wider spectral range (1.0 to 1.5 microns vs 0.9 to 1.2 microns) and higher temperatures (7600 K in the plasma torch versus 6700 K in the shock-tube). These higher temperatures in the present experiment have made it possible to observe high-lying excited NO states that were previously undetectable. These measurements are currently being extended up to 5 microns, with particular attention paid to the rovibronic bands of ground state NO, molecular continua, CO transitions, and other systems of importance. Publications and presentations resulting from or related to this work are cited in Section 3, and Section 4 lists the personnel who contributed to this report.
The Space Shuttle solid rocket motor case assembly joints are sealed using conventional 0-ring seals. The 5500+F combustion gases are kept a safe distance away from the seals by thick layers of insulation. Special joint-fill compounds are used to fill the joints in the insulation to prevent a direct flowpath to the seals. On a number of occasions. NASA has observed in several of the rocket nozzle assembly joints hot gas penetration through defects in the joint- fill compound. The current nozzle-to-case joint design incorporates primary, secondary and wiper (inner-most) 0-rings and polysulfide joint-fill compound. In the current design, 1 out of 7 motors experience hot gas to the wiper 0-ring. Though the condition does not threaten motor safety, evidence of hot gas to the wiper 0-ring results in extensive reviews before resuming flight. NASA and solid rocket motor manufacturer Thiokol are working to improve the nozzle-to-case joint design by implementing a more reliable J-leg design and a thermal barrier, This paper presents burn-resistance, temperature drop, flow and resiliency test results for several types of NASA braided carbon-fiber thermal barriers. Burn tests were performed to determine the time to burn through each of the thermal barriers when exposed to the flame of an oxy-acetylene torch (5500 F), representative of the 5500 F solid rocket motor combustion temperatures. Thermal barriers braided out of carbon fibers endured the flame for over 6 minutes, three times longer than solid rocket motor burn time. Tests were performed on two thermal barrier braid architectures, denoted Carbon-3 and Carbon-6, to measure the temperature drop across and along the barrier in a compressed state when subjected to the flame of an oxyacetylene torch. Carbon-3 and Carbon-6 thermal barriers were excellent insulators causing temperature drops through their diameter of up to a 2800 and 2560 F. respectively. Gas temperature 1/4" downstream of the thermal barrier were within the downstream Viton 0-ring temperature limit of 600 F. Carbon-6 performed extremely well in subscale rocket "char" motor tests when subjected to hot gas at 3200 F for an 11 second rocket firing, simulating the maximum downstream joint cavity fill time. The thermal barrier reduced the incoming hot gas temperature by 2200 F in an intentionally oversized gap defect, spread the incoming jet flow, and blocked hot slag, thereby offering protection to the downstream 0-rings.
Ultra-high temperature ceramics (UHTC) are of interest for hypersonic vehicle leading edge applications. Monolithic UHTCs are of concern because of their low fracture toughness and brittle behavior. UHTC composites (UHTCC) are being investigated as a possible approach to overcome these deficiencies. In this study a small sample of a UHTCC was evaluated by limited mechanical property tests, furnace oxidation exposures, and oxidation exposures in a flowing environment generated by an oxy-acetylene torch. The composite was prepared from a carbon fiber perform using ceramic particulates and a pre-cerns about microcracking due to thermal expansion mismatch between the matrix and the carbon fiber reinforcements, and about the oxidation resistance of the HfB2-SiC coating layer and the composite constituents. However, positive performance in the torch test warrants further study of this concept.