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Simple modification yields welds of better quality. Reed valve halves fluctuations in pressure in back-purge chamber attached to workpiece undergoing keyhole plasma arc welding. Identical to one used in fuel system of two-cycle gasoline engine. Backbead smoother, and weld penetrates more uniformly.
Significant advantages of the Variable Polarity Plasma Arc (VPPA) Welding Process include faster welding, fewer repairs, less joint preparation, reduced weldment distortion, and absence of porosity. The power distribution was analyzed for an argon plasma gas flow constituting the fluid in the VPPA Welding Process. The major heat loss at the torch nozzle is convective heat transfer; in the space between the outlet of the nozzle and the workpiece; radiative heat transfer; and in the keyhole in the workpiece, convective heat transfer. The power absorbed at the workpiece produces the molten puddle that solidifies into the weld bead. Crown and root widths, and crown and root heights of the weld bead are predicted. The basis is provided for an algorithm for automatic control of VPPA welding machine parameters to obtain desired weld bead dimensions.
The present conference discusses such topics in spacecraft welding as the NASA Long Duration Exposure Facility's evidence on material properties degradation, EVA/telerobotic construction techniques, welding of the superfluid helium on-orbit transfer flight demonstration tanks and hardware, electron-beam welding of aerospace vehicles, variable-polarity plasma arc keyhole welding of Al, aircraft experiments of low-gravity fusion welding, flash-butt welding of Al alloys, and a computer-aided handbook for space welding fabrication. Also discussed are the welded nozzle extension for Ariane launch vehicles, the existence of on-orbit cold-welding, structural materials performance in long-term space service, high-strength lightweight alloys, steels, and heat-resistant alloys for aerospace welded structures, the NASA-Goddard satellite repair program, and the uses of explosion welding and cutting in aerospace engineering.
Optical-emission spectrometric apparatus used to monitor variable-polarity plasma arc welding of aluminum alloys. Spectrometer incorporated into control system to ensure quality of weld because in keyhole, arc fully penetrates weld joint and impurities flushed out. Apparatus helps ensure high quality of weld by monitoring such contaminants as oxygen and hydrogen in shield gas, detecting inadequate flow of shield gas, and sensing changes in temperature of arc with changes in arc current and voltage.
Inert-gas diffuser provides protective gas cover for weld bead as it cools. Follows welding torch, maintaining continuous flow of argon over newly formed joint and prevents it from oxidizing. Helps to ensure welds of consistently high quality. Devised for plasma arc keyhole welding of plates of 0.25-in. or greater thickness, also used in tungsten/inert-gas and other plasma or arc welding processes.
Through the two phases of this contract, sensors for welding applications and parameter extraction algorithms have been developed. These sensors form the foundation of a weld control system which can provide action weld control through the monitoring of the weld pool and keyhole in a VPPA welding process. Systems of this type offer the potential of quality enhancement and cost reduction (minimization of rework on faulty welds) for high-integrity welding applications. Sensors for preweld and postweld inspection, weld pool monitoring, keyhole/weld wire entry monitoring, and seam tracking were developed. Algorithms for signal extraction were also developed and analyzed to determine their application to an adaptive weld control system. The following sections discuss findings for each of the three sensors developed under this contract: (1) weld profiling sensor; (2) weld pool sensor; and (3) stereo seam tracker/keyhole imaging sensor. Hardened versions of these sensors were designed and built under this contract. A control system, described later, was developed on a multiprocessing/multitasking operating system for maximum power and flexibility. Documentation for sensor mechanical and electrical design is also included as appendices in this report.
Improved chambers for inert-gas purging of back sides of workpieces during plasma arc welding in keyhole (full-penetration) mode based on concept of directing flows of inert gases toward, and concentrating them on, hot weld zones. Tapered chamber concentrates flow of inert gas on plasma arc plume and surrounding metal.
Plasma-arc welding torch modified to create vortex in plasma gas to focus arc into narrower and denser column. Swirl ring contains four channels with angled exit holes to force gas to swirl as it flows out of torch past tip of electrode. Degradation of electrode and orifice more uniform and need to rotate torch during operation to compensate for asymmetry in arc reduced or eliminated. Used in both keyhole and nonkeyhole welding modes.
Modified flow diffusers built for inert-gas purging of welds made with 5-kW CO(2) lasers operating with line-focus optics in conduction mode instead of with point-focus optics in customary keyhole mode. Diffusers made of copper components brazed together, robust enough to withstand strong reflections of line-focused laser energy.
Al-Li alloys offer the benefits of increased strength, elastic modulus and lower densities as compared to conventional aluminum alloys. Martin Marietta Laboratories has developed an Al-Li alloy designated 2195 which is designated for use in the cryogenic tanks of the space shuttle. The Variable Polarity Plasma Arc (VPPA) welding process is currently being used to produce these welds [1]. VPPA welding utilizes high temperature ionized gas (plasma) to transfer heat to the workpiece. An inert gas, such as Helium, is used to shield the active welding zone to prevent contamination of the molten base metal with surrounding reactive atmospheric gases. [1] In the Space Shuttle application, two passes of the arc are used to complete a butt-type weld. The pressure of the plasma stream is increased during the first pass to force the arc entirely through the material, a practice commonly referred to as keyholing. Molten metal forms on either side of the arc and surface tension draws this liquid together as the arc passes. 2319 Al alloy filler material may also be fed into the weld zone during this pass. During the second pass, the plasma stream pressure is reduced such that only partial penetration of the base material is obtained. Al 2319 filler material is added during this pass to yield a uniform, fully filled welded joint. This additional pass also acts to alter the grain structure of the weld zone to yield a higher strength joint.
The NASA/NOAA Electronic Theater presents Earth science observations and visualizations in a historical perspective. Fly in from outer space to South Africa, Cape Town and Johannesburg using NASA Terra/MODIS data, Landsat data and 1 m IKONOS 'Spy Satellite' data. Zoom in to any place South Africa using Earth Viewer 3D from Keyhole Inc. and Landsat data at 30 m resolution. Go back to the early weather satellite images from the 1960s and see them contrasted with the latest US and international global satellite weather movies including hurricanes and 'tornadoes'. See the latest visualizations of spectacular images from NASA/NOAA remote sensing missions like Terra, GOES, TRMM, SeaWiFS, Landsat 7 including 1 - min GOES rapid scan image sequences of Nov 9th 2001 Midwest tornadic thunderstorms and have them explained.
The NASA/NOAA Electronic Theater presents Earth science observations and visualizations in a historical perspective. Fly in from outer space to South Africa, Cape Town and Johannesburg using NASA Terra MODIS data, Landsat data and 1m IKONOS "Spy Satellite" data. Zoom in to any place South Africa using Earth Viewer 3D from Keyhole Inc. and Landsat data at 30 m resolution. Go back to the early weather satellite images from the 1960s and see them contrasted with the latest US and international global satellite weather movies including hurricanes & "tornadoes". See the latest visualizations of spectacular images from NASA/NOAA remote sensing missions like Terra, GOES, TRMM, SeaWiFS, Landsat 7 including 1 - min GOES rapid scan image sequences of Nov 9th 2001 Midwest tornadic thunderstorms and have them explained. See how High-Definition Television (HDTV) is revolutionizing the way we present science to the public. See dust storms and flooding in Africa and smoke plumes from fires in Mexico. See visualizations featured on the covers of Newsweek, TIME, National Geographic, Popular Science & on National & International Network TV. New computer software tools allow us to roam & zoom through massive global images e.g. Landsat tours of the US, and Africa, showing desert and mountain geology as well as seasonal changes in vegetation. See animations of the north and south polar ice packs and with icebergs on the coasts of Greenland and off the coast of Antarctica. Spectacular new visualizations of the global land, atmosphere & oceans are shown. Listen to the pulse of our planet. See how land vegetation, ocean plankton, clouds and temperatures respond to the sun & seasons. See vortexes and currents in the global oceans that bring up the nutrients to feed tiny algae and draw the fish, whales and fisherman. See the how the ocean blooms in response to these currents and El Nino/La Nina climate changes. See the city lights, fishing fleets, gas flares and biomass burning of the Earth at night observed by the "night-vision" DMSP military satellite. The presentation will be made using the latest HDTV and video projection technology that is now done from a laptop computer through an entirely digital path.
The NASA/NOAA Electronic Theater presents Earth science observations and visualizations in a historical perspective. Fly in from outer space to South Africa, Cape Town and Johannesburg using NASA Terra/MODIS data, Landsat data and 1 m IKONOS 'Spy Satellite' data. Zoom in to any place South Africa using Earth Viewer 3D from Keyhole Inc. and Landsat data at 30 m resolution Go back to the early weather satellite images from the 1960s and see them contrasted with the latest US and international global satellite weather movies including hurricanes & 'tornadoes'. See the latest visualizations of spectacular images from NASANOAA remote sensing missions like Terra, GOES, TRMM, SeaWiFS, Landsat 7 including 1 - min GOES rapid scan image sequences of Nov 9th 2001 Midwest tornadic thunderstorms and have them explained.
The physical principles of PAW from basic arcs to keyholing to variable polarity are outlined. A very brief account of the physics of PAW with an eye to the needs of a welder is presented. Understanding is usually (but not always) superior to handbooks and is required (unless dumb luck intervenes) for innovation. And, in any case, all welders by nature desire to know. A bit of history of the rise and fall of the Variable Polarity (VP) PA process in fabrication of the Space Shuttle External Tank is included.
The NASA/NOAA Electronic Theater presents Earth science observations and visualizations from space in a historical perspective. Fly in from outer space to Athens and site of the 2004 Summer Olympics and the Far East using 1 m IKONOS "Spy Satellite" data. Contrast the 1972 Apollo 17 "Blue Marble" image of the Earth with the latest US and International global satellite images that allow us to view our Planet from any vantage point. See the latest spectacular images from NASA/NOAA/Commercial remote sensing missions like Terra, GOES, TRMM, SeaWiFS, & Landsat 7, QuickBird of the SE Asia Tsunami, devastation of Hurricane Katrina this year in New Orleans, and the LA/San Diego Fires of 2003. See how High Definition Television (HDTV) is revolutionizing the way we do science communication. Take the pulse of the planet on a daily, annual and 30-year time scale. See daily thunderstorms, the annual blooming of the northern hemisphere land masses and oceans, fires in Africa, dust storms in Iraq, and carbon monoxide exhaust from global burning. See visualizations featured on Newsweek, TIME, National Geographic, Popular Science covers & National & International Network TV. Spectacular new global visualizations of the observed and simulated atmosphere & oceans are shown. See the currents and vortexes in the oceans that bring up the nutrients to feed tiny plankton and draw the fish, whales and fishermen. See the how the ocean blooms in response to El Nino/La Nina climate changes. The Etheater will be presented using the latest High Definition TV (HDTV) and video projection technology on a large screen. See city lights around the globe and in your area observed by the "night-vision" DMSP satellite, Also see how Keyhole and Google Maps are using satellite and aerial photography to help you find your house and plan your vacation.
The OnMoon server is a computer program that provides Internet access to high-resolution Lunar images, maps, and elevation data, all suitable for use in geographical information system (GIS) software for generating images, maps, and computational models of the Moon. The OnMoon server implements the Open Geospatial Consortium (OGC) Web Map Service (WMS) server protocol and supports Moon-specific extensions. Unlike other Internet map servers that provide Lunar data using an Earth coordinate system, the OnMoon server supports encoding of data in Moon-specific coordinate systems. The OnMoon server offers access to most of the available high-resolution Lunar image and elevation data. This server can generate image and map files in the tagged image file format (TIFF) or the Joint Photographic Experts Group (JPEG), 8- or 16-bit Portable Network Graphics (PNG), or Keyhole Markup Language (KML) format. Image control is provided by use of the OGC Style Layer Descriptor (SLD) protocol. Full-precision spectral arithmetic processing is also available, by use of a custom SLD extension. This server can dynamically add shaded relief based on the Lunar elevation to any image layer. This server also implements tiled WMS protocol and super-overlay KML for high-performance client application programs.
The OnMars server is a computer program that provides Internet access to high-resolution Mars images, maps, and elevation data, all suitable for use in geographical information system (GIS) software for generating images, maps, and computational models of Mars. The OnMars server is an implementation of the Open Geospatial Consortium (OGC) Web Map Service (WMS) server. Unlike other Mars Internet map servers that provide Martian data using an Earth coordinate system, the OnMars WMS server supports encoding of data in Mars-specific coordinate systems. The OnMars server offers access to most of the available high-resolution Martian image and elevation data, including an 8-meter-per-pixel uncontrolled mosaic of most of the Mars Global Surveyor (MGS) Mars Observer Camera Narrow Angle (MOCNA) image collection, which is not available elsewhere. This server can generate image and map files in the tagged image file format (TIFF), Joint Photographic Experts Group (JPEG), 8- or 16-bit Portable Network Graphics (PNG), or Keyhole Markup Language (KML) format. Image control is provided by use of the OGC Style Layer Descriptor (SLD) protocol. The OnMars server also implements tiled WMS protocol and super-overlay KML for high-performance client application programs.
A proposed system of tooling, machinery, and control equipment would be capable of performing any of several friction stir welding (FSW) and friction plug welding (FPW) operations. These operations would include the following: Basic FSW; FSW with automated manipulation of the length of the pin tool in real time [the so-called auto-adjustable pin-tool (APT) capability]; Self-reacting FSW (SRFSW); SR-FSW with APT capability and/or real-time adjustment of the distance between the front and back shoulders; and Friction plug welding (FPW) [more specifically, friction push plug welding] or friction pull plug welding (FPPW) to close out the keyhole of, or to repair, an FSW or SR-FSW weld. Prior FSW and FPW systems have been capable of performing one or two of these operations, but none has thus far been capable of performing all of them. The proposed system would include a common tool that would have APT capability for both basic FSW and SR-FSW. Such a tool was described in Tool for Two Types of Friction Stir Welding (MFS- 31647-1), NASA Tech Briefs, Vol. 30, No. 10 (October 2006), page 70. Going beyond what was reported in the cited previous article, the common tool could be used in conjunction with a plug welding head to perform FPW or FPPW. Alternatively, the plug welding head could be integrated, along with the common tool, into a FSW head that would be capable of all of the aforementioned FSW and FPW operations. Any FSW or FPW operation could be performed under any combination of position and/or force control.