Fatigue Characteristics of Spot-welded 24S-T Aluminum Alloy
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An Assessment of Molten Metal Detachment Hazards During Electron Beam Welding in Space
The safety issue has been raised with regards to potential molten metal detachments from the weld pool and cold filler wire during electron beam welding in space. This investigation was undertaken to evaluate if molten metal could detach and come in contact with astronauts and burn through the fabric of the astronauts' Extravehicular Mobility Unit (EMU) during electron beam welding in space. Molten metal detachments from either the weld/cut substrate or weld wire could present harm to a astronaut if the detachment was to burn through the fabric of the EMU. Theoretical models were developed to predict the possibility and size of the molten metal detachment hazards during the electron beam welding exercises at Low Earth Orbit (LEO). The primary molten metal detachment concerns were those cases of molten metal separation from the metal surface due to metal cutting, weld pool splashing, entrainment and release of molten metal due to filler wire snap-out from the weld puddle, and molten metal accumulation and release from the end of the weld wire. Some possible ways of obtaining molten metal drop detachments would include an impulse force, or bump, to the weld sample, cut surface, or filler wire. Theoretical models were developed for these detachment concerns from principles of impact and kinetic energies, surface tension, drop geometry, surface energies, and particle dynamics. The surface tension represents the force opposing the liquid metal drop from detaching whereas the weight of the liquid metal droplet represents a force that is tending to detach the molten metal drop. Theoretical calculations have indicated that only a small amount of energy is required to detach a liquid metal drop; however, much of the energy of an impact is absorbed in the sample or weld plate before it reaches the metal drop on the cut edge or surface. The tendency for detachment is directly proportional to the weld pool radius and metal density and inversely proportional to the surface tension of the liquid metal. For a detachment the initial kinetic energy of the weld pool with respect to the plate has to exceed the energy to form the extra surface required for the detachment of the pool. The difficulty is in transferring the energy from the point of impact through the plate and sample to the cut edge. It is likely that not all of the kinetic energy is available for detaching the pool; some may be sequestered in weld pool oscillations. The coefficient of restitution for the collision will be lower than one if irreversible deformation, for example plastic flow deformation, takes place during the collision. Thus determining the amount of energy from an impact that actually reaches the molten metal droplet is critical. Various molten metal detachment scenarios were tested experimentally in an enclosed vacuum chamber using the Ukrainian Universal Hand Tool, an electron beam welder designed for space welding. The experimental testing was performed in a 4 ft. X 4 ft. vacuum chamber at Marshall Space Flight Center, evacuated to vacuum levels of at least 50 microTorr, and also some welding garment material was utilized to observe the effect of the molten metal detachments on the material. A "carillon" apparatus consisting of four pendulum hammer strikers, each weighing approximately 3.65 lbs, raised to predetermined specific heights was used to apply an impact force to the weld sample/plate during electron beam welding and cutting exercises. The strikers were released by switching on an electric motor to rotate a pin holding wires retaining the strikers at desired heights. The specimens were suspended so as to be free to respond to the blows with a sudden velocity increment. The specimens were mounted on a hinged plate for minimizing effective mass with the option to fasten it down so as to raise its effective mass closer to that anticipated for an actual space welding scenario. Measurements were made of the impact energy and the horizontal fling distances of the detached metal drops. It was not particularly easy to generate the detachments for this experiment. This document presents the details of the theoretical modeling effort and a summary of the experimental effort to measure molten metal drop detachments from terrestrial electron beam welding in the enclosed vacuum chamber. The results of the experimental effort have shown that molten metal detachments can occur from the sample/weld plate only if a sufficiently large impact force is applied to the weld plate. A "weld pool detachment parameter" was determined to indicate whether detachment would occur. Detachment can be either full or partial (dripping), Partial detachment means that the weld pool detached from one side of the liquid-solid boundary so as to leave a hole at the puddle site but remained attached over part of the liquid-solid boundary and dripped down the plate with no fully detached material detected. Full detachment, however, does not necessarily mean that the whole pool fully detached; in some cases only a smaller portion of the pool detached, the remainder dripping down the plate. The weld pool detachment parameter according to theory and according to the empirical data allows a determination of whether full detachments might occur. Theoretical calculations indicated titanium alloy would be the most difficult from which to detach molten metal droplets followed by stainless steel and then by aluminum. The experimental results were for the most part consistent with the theoretical analysis and predictions. The above theory is applicable to other situations as desired for assessing the potential for molten metal detachments.
Fragomeni, James M.↗
Evaluation of residual stresses in isothermal friction stir welded 304L stainless steel plates
Friction stir welding was performed on 304L SS plates in order to heal simulated cracks created by electrical discharge machining. Two different tool temperatures (825 and 725 °C) were chosen for this study. Both neutron diffraction and X-ray diffraction techniques were employed to evaluate the residual stresses along two orthogonal reference directions, longitudinal (syy) and transverse (sxx). The former technique was also used to measure residual stresses at various depths. It was found that, at 1 mm depth from the top surface inside the stir zone (SZ), the longitudinal component was tensile in nature while the transverse component was compressive. The nature and magnitude of the residual stress fields, and the position of the peak residual stresses were found to vary with the weld depth. The SZ of the 725 °C weld exhibited higher peak stress than 825 °C weld mainly due to a lack of stress relief at the lower temperature.
Friction stir welding, Steel↗
The cause of welding cracks in aircraft steels
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.
Muller, J↗
Nondestructive testing of electro thermal devices
This paper describes the results of a recent investigation into 'thermal time constant' nondestructive testing of high reliability electrical fuses. The use of established nondestructive test technology for examining the quality and firing characteristics of electro-explosive devices has been successfully applied to the inspection and prediction of the functional performance of electrical fuses. The technique requires application of a low level current pulse to the electrical fuse with an oscilloscope display of the curve as generated by the temperature coefficient of resistance feedback. The heating curve of temperature vs time is composed of one predominant thermal time constant, which is the product of the test unit's thermal capacity and thermal resistance. It has been found that the quality of the individual electrical fuse, for instance, the relative condition of the critical internal weld or solder joint, can be examined nondestructively.
Earnest, J. E., Jr.↗
Overview of the SP-100 Program
Technical progress made by the SP-100 Program over the past five years is reviewed. The following advances are discussed: (1) development of the fuel pin which is the thermal power producing component in the system; (2) development of the conductively coupled multi-couple thermoelectric cell components; (3) verification of the predicted structural and electrical performance of the thermoelectric cells; (4) development of fabricating and welding niobium alloy, NblZr and NblZr.1C to verify the containment of lithium in space vacuum with no leakage, (5) the containment of nitrogen in the fuel with accurate stoichiometric control and bonded rhenium liners, (6) system mass reduction of 15 percent; and (7) the development of high-temperature, low-cost, low-mass heat pipes for heat rejection to space.
Mondt, Jack F.↗
Bonding and joining technology - A compilation
Compilation of technical information including metallurgy, electrical repair, fabrication techniques for coating, bonding and brazing, and electron beam welding
Source record↗
Resistance-Welding Test Fixture
Realistic welding conditions produce reliable specimens. Simple fixture holds resistance-welding test specimens. Specimen holder includes metallic holder and clamps to provide electrical and thermal paths and plastic parts providing thermal and electrical isolation.
Brennan, Andrew D.↗
Mechanical Design of the PIP-II ORBUMP Pulsed Dipole Magnet
The Proton Improvement Plan-II (PIP-II) is a vital upgrade to Fermilab's accelerator complex. The upgrade is designed to power the world s most intense high-energy neutrino beam in future experiments. The magnet pulse repetition rate of the PIP-II injection system is being upgraded from 15 Hz to 20 Hz and requires a roughly 30% increase in the magnetic field of the new Orbital Bump (ORBUMP) magnets in the Booster. The magnet is secured in a vacuum box and the core is made up of 0.127 mm thick, low carbon steel laminations with a C-5 inorganic coating. The core is clamped using external tie bars welded to the core end plates. ANSYS Finite Element Analysis (FEA) was used to evaluate the clamping design to minimize the deflection of the core post welding of the tie bars. The water-cooled single turn coil is electrically isolated from the core using virgin PEEK insulating material in the gap. An investigation into the high voltage performance of the virgin PEEK insulator was conducted. The design of the coil which shapes the magnetic field by acting as the pole tips is critical for the integrated field homogeneity. The coil manufacturing tolerances and fabrication techniques were evaluated to ensure the magnetic properties of the magnet could be obtained. The ORBUMP magnet mechanical design is presented in this paper.
Karas, Dino [Fermilab] (ORCID:0000000304340670)↗
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.↗
Substantially Oxygen-Free Contact Tube
A device for arc welding is provided in which a continuously-fed electrode wire is in electrical contact with a contact tube. The contact tube is improved by using a substantially oxygen-free conductive alloy in order to reduce the amount of electrical erosion.
Pike, James F.↗
Substantially oxygen-free contact tube
A device for arc welding is provided in which a continuously-fed electrode wire is in electrical contact with a contact tube. The contact tube is improved by using a substantially oxygen-free conductive alloy in order to reduce the amount of electrical erosion.
Pike, James F.↗
Operation, maintenance, and installation instructions for HLW thermal catalytic oxidizer/reducer (TCO)
The HLW TCO Units are a combination of four rectangular vessels; the Recuperative Heat Exchanger, Electric Heater, Selective Catalytic Oxidizer (SCO), and the Selective Catalytic Reducer (SCR). Each housing is simply a closed rectangular box with formed angle stiffeners welded to the outside perimeter. The housings are connected with process piping and sit on a skid. There is an external frame to support all major process piping and the Electric Heater. The process piping consists of a 14" inlet which enters the heat exchanger. Then the off-gas flows through 18" cross over piping which leads to the heater. Once the off-gas is heated, another section of 18" process piping leads the off-gas through the SCO and SCR. The off-gas then flows through the heat exchanger before exiting through 16" process piping which leads to the customer's piping. The other equipment associated with the HLW TCO is the Ammonia Dilution Skid. The dilution skid controls the ammonia injection into the off-gas. The dilution skid supports two process lines, a 2" line and a 1" line which carries process air and anhydrous ammonia respectively. Ammonia injection into the off-gas is required prior to entering the SCR to ensure the NOx reduction occurs through the SCR catalyst bank.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
A FEASIBILITY STUDY ON CRACK REPAIR IN AUSTENITIC STAINLESS STEEL DRY STORAGE CANISTERS USING ISOTHERMAL FRICTION STIR WELDING
In recent time, solid state crack repair techniques in spent nuclear fuel dry storage canisters (SNF-DSC) have garnered significant interest. Plates of austenitic stainless steels are usually arc welded to fabricate the cylindrical canisters which are prone to chloride-induced stress corrosion cracking. Friction stir welding (FSW) is considered to be a potential candidate for damage repair. In this work, electrical discharge machining was used to simulate cracks in 304L stainless steel plates of 12.7 mm thickness. Subsequently, isothermal FSW was carried out at two different temperatures (725 and 825°C) in order to repair the simulated crack. Microstructure-mechanical property correlations in FSWed plates were studied in detail. Significant grain refinement observed in the stir zone (SZ) was attributed to dynamic recrystallization occurring during FSW. A comparison of Vickers microhardness showed higher hardness and homogeneity in the 725°C SZ than its 825°C counterpart. The fraction of S3 boundary is found to be low in the SZ as compared to base metal (BM). Yield strength of the joints was found to be approximately 100 MPa higher than that of the BM accompanied by a drop in ductility by a factor of 2. Residual stress profile across 825°C weld was measured using x-ray diffraction.
Bhattacharyya, Madhumanti↗
Intrinsic thermal interfacial resistance measurement in bonded metal–polymer foils
Heat conduction through bonded metal–polymer interfaces often limits the overall heat transfer in electronic packaging, batteries, and heat recovery systems. To design the thermal circuit in such systems, it is essential to measure the thermal interfacial resistance (TIR) across ~1 µm to 100 µm junctions. Previously reported TIR of metal–polymer junctions utilize ASTM E1530-based two-block systems that measure the TIR by applying pressure across the interface through external heating and cooling blocks. Here, we report a novel modification of the ASTM-E1530 technique that employs integrated heaters and sensors to provide an intrinsic TIR measurement of an adhesively bonded metal–polymer junction. We design the measurement technique using finite element simulations to either passively suppress or actively compensate the lateral heat diffusion through the polymer, which can minimize the systematic error to ≲5%. Through proof-of-concept experiments, we report the TIR of metal–polymer interfaces made from DuPont’s Pyralux double-side copper-clad laminates, commonly used in flexible printed circuit boards. Our TIR measurement errors are <10%. We highlight additional sources of errors due to non-idealities in the experiment and discuss possible ways to overcome them. Our measurement technique is also applicable to interfaces that are electrically insulating such as adhesively joined metal–metal junctions and sputter-coated or welded metal–polymer junctions. Altogether, the technique is capable of measuring TIR ≳10 –5 m 2 KW –1 in bonded metal–polymer foils and can be tailored for in situ measurements in flexible electronics, circuit packaging, and other hybrid metal–polymer systems.
47 OTHER INSTRUMENTATION↗
Sail GTS ground system analysis: Avionics system engineering
A comparison of two different concepts for the guidance, navigation and control test set signal ground system is presented. The first is a concept utilizing a ground plate to which crew station, avionics racks, electrical power distribution system, master electrical common connection assembly and marshall mated elements system grounds are connected by 4/0 welding cable. An alternate approach has an aluminum sheet interconnecting the signal ground reference points between the crew station and avionics racks. The comparison analysis quantifies the differences between the two concepts in terms of dc resistance, ac resistance and inductive reactance. These parameters are figures of merit for ground system conductors in that the system with the lowest impedance is the most effective in minimizing noise voltage. Although the welding cable system is probably adequate, the aluminum sheet system provides a higher probability of a successful system design.
Lawton, R. M.↗
Alignment Tool For Inertia Welding
Compact, easy-to-use tool aligns drive bar of inertia welder over hole in stub. Ensures drive bar concentric to hole within 0.002 in. (0.051 mm.). Holds two batteries and light bulb. Electrical circuit completed, providing current to bulb when pin in contact with post. When pin centered in post hole, it does not touch post, and lamp turns off. Built for use in making repair welds on liquid-oxygen-injector posts in Space Shuttle main engine. Version having suitably modified dimensions used to facilitate alignment in other forests of post.
Snyder, Gary L.↗
Shrink-Fit Solderable Inserts Seal Hermetically
Shrink-fit stainless-steel insert in aluminum equipment housing allows electrical connectors to be replaced by soldering, without degrading hermeticity of housing or connector. Welding could destroy electrostatic-sensitive components and harm housing and internal cables. Steel insert avoids problems because connector soldered directly to it rather than welded to housing. Seals between flange and housing, and between connector and flange resistant to leaks, even after mechanical overloading and thermal shocking.
Croucher, William C.↗