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Technique yields joints with average transmissivity of 91.6 percent. Electric arc passed over butted fiber ends to melt them together. Maximum optical transmissivity of joint achieved with optimum choice of discharge current, translation speed, and axial compression of fibers. Practical welding machine enables delicate and tedious joining operation performed routinely.
Explosive seam welding produces up to 100-percent joint strength. Ribbon explosive activated by remote energy source produces metallurgically sound joint. Success of technique verified for joints between like metals and joints between two different metals. Applications include structural assembly in toxic atmospheres and in radioactive or otherwise hazardous environments.
In order to establish permanent human presence in space technologies of constructing and repairing space stations and other space structures must be developed. Most construction jobs are performed on earth and the fabricated modules will then be delivered to space by the Space Shuttle. Only limited final assembly jobs, which are primarily mechanical fastening, will be performed on site in space. Such fabrication plans, however, limit the designs of these structures, because each module must fit inside the transport vehicle and must withstand launching stresses which are considerably high. Large-scale utilization of space necessitates more extensive construction work on site. Furthermore, continuous operations of space stations and other structures require maintenance and repairs of structural components as well as of tools and equipment on these space structures. Metal joining technologies, and especially high-quality welding, in space need developing.
Special tooling alines and holds internally-stiffened large-diameter cylindrical parts for welding. Alinement brackets attached to strengthening fins on insides of cylindrical tank sections. Jackscrews on brackets raised or lowered to eliminate mismatches between adjacent sections. Tooling substantially reduces costs while allowing more precise control and improved quality.
A long duration test was conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules were thermally cycled for 36,000 cycles between -80 and +80 C. The environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the earth's shadow was simulated. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived this extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.
The fabrication of multilayer fiber composites by explosive welding is characterized by intense plastic deformation of the matrix material as it fills the spaces between fibers and by high velocity of the collision between matrix layers due to acceleration in the channels between fibers. The plastic deformation of the matrix layers and fiber-matrix friction provide mechanical and thermal activation of the contact surfaces, which contributes to the formation of a bond. An important feature of the process is that the fiber-matrix adhesion strength can be varied over a wide range by varying the parameters of impulsive loading.
A long duration test has been conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules have been thermally cycled for 36,000 cycles between -80 and +80 C on this JPL and NASA Lewis Research Center sponsored work. This test simulates the environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the Earth's shadow. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived his extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.
Solar cell modules with welded and soldered interconnections were constructed using a flexible substrate material. These modules were thermally cycled between approx. 80 deg C at rates 100 cycles/day to demonstrate survivability under simulated low Earth orbit (LEO) temperature conditions. The modules, cycled in an inert atmosphere, show durability for 36,000 cycles.
This three-phase study was directed at developing a fitness for service defect acceptance criteria for welds with defect indications. The study focussed on A106 Gr. B steel pipe. The first phase involved a literature search and critical review to develop the preliminary acceptance criteria to the extent permitted by the data. The second phase developed data for flat plate, wall segment, and vessel specimens containing artificial or natural planar or volumetric defects. The final phase developed acceptance criteria from the test data.
The application of robots to complex on-orbit tasks will require a high degree of adaptability. This paper describes a project which is developing very adaptive robotic systems for welding of the Space Shuttle main engine. A number of the developments which will arise from this program will serve as useful starting points for more advanced systems to be used on-orbit.
Computer program ROBOSIM, developed to simulate operations of robots, applied to preliminary design of robotic arc-welding operation. Limitations on equipment investigated in advance to prevent expensive mistakes. Computer makes drawing of robotic welder and workpiece on positioning table. Such numerical simulation used to perform rapid, safe experiments in computer-aided design or manufacturing.
Solution changes color if heat-treated condition lost. Simple test indicates whether welded joint retained its postweld heat-treated condition after reworking including rewelding and grinding. Test used instead of Rockwell or Brinell hardness tests when reworked surface inaccessible to hardness-testing apparatus or when small surface imperfections created by apparatus unacceptable.
Industrial radiography is a well established, reliable means of providing nondestructive structural integrity information. The majority of industrial radiographs are interpreted by trained human eyes using transmitted light and various visual aids. Hundreds of miles of radiographic information are evaluated, documented and archived annually. In many instances, there are serious considerations in terms of interpreter fatigue, subjectivity and limited archival space. Quite often it is difficult to quickly retrieve radiographic information for further analysis or investigation. Methods of improving the quality and efficiency of the radiographic process are being explored, developed and incorporated whenever feasible. High resolution cameras, digital image processing, and mass digital data storage offer interesting possibilities for improving the industrial radiographic process. A review is presented of computer aided radiographic interpretation technology in terms of how it could be used to enhance the radiographic interpretation process in evaluating radiographs of aluminum welds.
This paper presents the results of a study directed at developing a data base for establishing fitness-for-purpose defect acceptance criteria for welds with defects. The study focused on A106 Grade B steel pipe. Data are presented for flat plate, wall segment, and vessel specimens and actual pipe sections containing either artificial or natural planar or volumetric defects. Defect acceptance criteria developed from the test data are discussed.
Report describes experimental study of some of the physical and chemical effects that occur during variable-polarity plasma arc (VPPA) keyhole welding of 2219 aluminum alloy. Comprised three major programs: (1) determination of effects of chemical additions (i.e., impurities) on structure and shape of bead and keyhole; (2) determination of flow in regions surrounding keyhole; (3) development of analog used easily to study flow in keyhole region.
Etching solution developed for use prior to type-IVc penetrant inspection of Incology(R) 903 weld overlays. Formulated as follows: 80 g ferric chloride hexahydrate, 300 mL reagent-grade hydrochloric acid, 25 mL food- or reagent-grade phosphoric acid, and 100 mL ethylene glycol. Gives more reasonable range of etching time and reduces probability of overetching and resulting damage. Stored indefinitely.
Welding-current indicator made of surface-mounted components on flexible circuit board. Holds variety of components on surface. After assembly, flexible circuit wrapped to fit around transformer core. Surface-mounted devices make it unnecessary to drill holes in circuit board to accommodate component leads. Use of small surface-mounted devices result in lightweight, compact indicator circuit.
Noncontacting, nondestructive computer tomography system determines internal and external contours of welded objects. System makes it unnecessary to take metallurgical sections (destructive technique) or to take silicone impressions of hidden surfaces (technique that contaminates) to inspect them. Measurements of contours via tomography performed 10 times as fast as measurements via impression molds, and tomography does not contaminate inspected parts.