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Feasibility study of using getters and hydrogen removers for hydrogen porosity reduction in arc welding aluminum alloy plates
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.
Photodetector or optical fiber leading to photodetector mounted inside gas/tungsten arc welding torch to monitor arc light reflected from oscillating surface of weld pool. Proposed optical monitoring components preserve compact profile of welding torch, maintained in fixed aim at weld-pool position at end of welding torch, and protected against bumping external objects.
Fabrication of columbium alloy liquid metal loop to study boiling and condensing characteristics of Na and K up to 1000 degrees F with gas tungsten arc welding in helium atmosphere
Fracture resistance of pipeline welds from a range of strength grades and welding techniques was measured in air and 21 MPa hydrogen gas, including electric resistance weld of X52, friction stir weld of X100 and gas metal arc welds (GMAW) of X52, X65 and X100. Welds exhibited a decrease in fracture resistance in hydrogen compared to complementary tests in air. A general trend was observed that fracture resistance in 21 MPa hydrogen gas decreased with increasing yield strength. To accommodate material constraints, two different fracture coupon geometries were used in this study, which were shown to yield similar fracture resistance values in air and 21 MPa hydrogen gas; values using different coupons resulted in less than 15% difference. In addition, fracture coupons were removed from controlled locations in select welds to examine the potential influence of orientation and residual stress. The two orientations examined in the X100 GMAW exhibited negligible differences in fracture resistance in air and, similarly, negligible differences in hydrogen. Residual stress exhibited a modest influence on fracture resistance; however, a consistent trend was not observed between tests in air and hydrogen, suggesting further studies are necessary to better understand the influence of residual stress. A comparison of welds and base metals tested in hydrogen gas showed similar susceptibility to hydrogen-assisted fracture. The overall dominant factor in determining the susceptibility to fracture resistance in hydrogen is the yield strength.
At the Materials and Life Science Experimental Facility (MLF) in J-PARC, liquid mercury target for the pulsed spallation neutron source is in operation. An enclosure vessel for the liquid mercury target made of type 316L stainless steel (SS316L) suffers two kinds of cyclic stress during operation. One is the thermal stress due to the internal heating and swings by proton beam trip. The other is the impulsive stress by the pressure waves generated by the proton beam injection. The total number of loading cycles for the former is ∼104, and the latter is ∼4 × 108 for a year operation in the J-PARC mercury target vessel. The target vessel is assembled by an electron beam welding (EBW) and a gas tungsten arc welding (GTAW). However, fatigue data of welded SS316L up to gigacycle is limited. Ultrasonic fatigue testing, applying load cycles by utilizing ultrasonic resonance, for the welded SS316L was performed to investigate the effect of welding on fatigue behavior up to a gigacycle. The result showed that the fatigue strength degradation by EBW and EBW with GTAW were not recognized up to 109 cycles. Crack initiation in welded specimens nucliated at off-center areas of the specimen whereas the cracks in base metal specimen originated at the specimen center.
Three exceptionally high toughness Fe-12Ni alloys designed for cryogenic service were welded by using the gas tungsten arc welding process. Evaluation of their weldability included equivalent energy fracture toughness tests, transverse weld tensile tests at -196 and 25 C, and weld crack sensitivity tests. The Fe-12Ni-0.25Ti alloy proved extremely weldable for cryogenic applications, having weld and heat affected zone properties comparable to those of the wrought base alloy. The Fe-12Ni-0.5Al alloy had good weld properties only after the weld joint was heat treated. The Fe-12Ni-0.25Nb alloy was not considered weldable for cryogenic use because of its poor weld joint properties at -196 C and its susceptibility to hot cracking.
Friction stir welding process is being evaluated for application on the Al-Cu-Li 2195 Super-Light Weight External Tank of the Space Transportation System. In the present investigation Al-Cu-Li 2195 plates were joined by autogenous friction stir welding (FSW) and hybrid FSW (friction stir welding over existing variable polarity plasma arc weld). Optical microscopy and transmission electron microscopy (TEM) were utilized to characterize microstructures of the weldments processed by both welding methods. TEM observations of autogenous FSW coupons in the center section of the dynamically-recrystallized zone showed an equiaxed recrystallized microstructure with an average grain size of approx. 3.8 microns. No T(sub 1), precipitates were present in the above-mentioned zone. Instead, T(sub B) and alpha precipitates were found in this zone with a lower population. Alternate immersion, anodic polarization, constant load, and slow strain tests were carried out to evaluate the general corrosion and stress-corrosion properties of autogenous and hybrid FSW prepared coupons. The experimental results will be discussed.
In 1996, NASA's Marshall Space Flight Center began an ambitious program designed to find alternative methods of repairing conventional TIG (Tungsten Inert Gas) welds and VPPA (Variable Polarity Plasma Arc) welds on the Space Shuttle External Tank without producing additional heat-related anomalies or conditions. Therefore, a relatively new method, invented by The Welding Institute (TWI) in Cambridge, England, called Friction Stir Welding (FSW), was investigated for use in this application, as well as being used potentially as an initial weld process. As with the conventional repair welding processes, nondestructive evaluation (NDE) plays a crucial role in the verification of these repairs. Since it was feared that conventional NDE might have trouble with this type of weld structure (due to shape of nugget, grain structure, etc.) it was imperative that a complete study be performed to address the adequacy of the NDE process. This paper summarizes that process.
In this welding test campaign, electron beam welding (EBW) and manual gas tungsten arc welding (GTAW) processes were utilized to join an additively manufactured aluminum alloy nozzle to a wrought aluminum flange. Both aluminum alloys were 6061, which in their conventional form are susceptible to solidification cracking issues. The AM nozzle utilized a novel high-performance modified version of 6061 which exhibits crack resistant properties during the AM process and during welding. When manually conducting GTAWs a filler wire with the same modified version of 6061 was utilized to weld different combinations of 6061 coupons (either modified or unmodified). Due to the grain refinement technology in the modified 6061, either as filler material or base material, there was complete elimination of weld solidification cracking. During EBW development a combination of wrought 6061 with a modified and additively manufactured 6061 was investigated. The EBWs developed exhibited no crack like defects. Each weld development program utilized non-destructive evaluation, metallography, and mechanical testing to determine the final weld acceptance. Mechanical testing involved hardness evaluation and tension testing on welded coupons. Both welding techniques were successfully developed and exhibited adequate properties for the final test articles and met all requirements of the development campaign. These welds were ultimately developed to be utilized on a set of all-aluminum liquid rocket nozzles to demonstrate additively manufactured aluminum alloys for propulsion applications. These aluminum nozzles were tested at NASA Marshall Space Flight Center’s hot fire test facility and subsequently underwent a test campaign involving a variety of chamber pressures and liquid propellant combinations. Following the hot fire test campaign each weldment was investigated for post operation performance and any defects that may have evolved during testing.
Gas tungsten arc welding experiments for improving properties of 2219 aluminum by adaptive control of workpiece temperature near molten puddle
NASA uses the Variable Polarity Plasma Arc Welding (VPPAW) process extensively for fabrication of Space Shuttle External Tanks. This welding process has been in use at NASA since the late 1970's but the physics of the process have never been satisfactorily modeled and understood. In an attempt to advance the level of understanding of VPPAW, Dr. Arthur C. Nunes, Jr., (NASA) has developed a mathematical model of the process. The work described in this report evaluated and used two versions (level-0 and level-1) of Dr. Nunes' model, and a model derived by the University of Alabama at Huntsville (UAH) from Dr. Nunes' level-1 model. Two series of VPPAW experiments were done, using over 400 different combinations of welding parameters. Observations were made of VPPAW process behavior as a function of specific welding parameter changes. Data from these weld experiments was used to evaluate and suggest improvements to Dr. Nunes' model. Experimental data and correlations with the model were used to develop a multi-variable control algorithm for use with a future VPPAW controller. This algorithm is designed to control weld widths (both on the crown and root of the weld) based upon the weld parameters, base metal properties, and real-time observation of the crown width. The algorithm exhibited accuracy comparable to that of the weld width measurements for both aluminum and mild steel welds.
Low transformation temperature welding (LTTW) consumables are characterized by a low martensite start temperature and a large fraction of martensite forming in the weld. It can efficiently reduce the tensile residual stress because the volume expansion associated with the martensitic transformation compensates for the thermal contraction during cooling. In this work, a LTTW wire, designated as EH200B, was created for the arc welding of advanced high-strength steel thin plates. In comparison to conventional ER70S-3 wires, this LTTW wire generated an opposite distortion pattern. Neutron diffraction measurements along the center thickness of the welded plates showed the maximum residual stress along the longitudinal direction (LD) in the weld region, and the heat-affected zone (HAZ) immediately adjacent to the weld region was reduced from ~330 MPa to below 240 MPa by using the LTTW wire. A finite element (FE) model was developed to predict the residual stress distributions of the plates welded under these two wires. The simulation results showed reasonable agreement with the volume-average neutron diffraction data. Compressive residual stress in the weld region using the LTTW wire was predicted by the FE method. Electron backscattered diffraction and x-ray diffraction measurements confirmed ~90% martensite was present in the LTTW weld. The fatigue life of DP980 steel lap joint panels using EH200B wire nearly doubled that of ER70S-3 wire. This improvement was attributed to the high strength and low LD residual stress in the weld and HAZ immediately adjacent to the weld.
Directed energy deposition (DED) is a form of additive manufacturing that uses localized melted metal, similar to traditional arc welding, to construct an object. In comparison to polymer systems, metal systems can exert additional control over the build process through manipulation of the pool of melted metal, called the “melt pool.” This is especially important to maintain appropriate layer heights and create high quality builds. Additionally, metal systems allow site-specific control of the printed part, which enables advanced construction techniques that would otherwise not be possible. However, both of these types of control require support from the slicing software and, potentially, sensor feedback. This chapter will discuss these control processes and their basic implementation in a slicing program. The processes described here lay the foundation for more advanced solutions, particularly sensor feedback, that will be discussed later.
It is pointed out that over 50 different alloys are used in construction of the space shuttle main engines (SSME). Primary construction of the SSME is by welding or brazing of wrought and cast components. Welding processes involve both gas tungsten-arc welds and electron-beam welds. Electroforming has been developed as a process to fabricate and bond structural members for the SSME. Important aspects in the selection of materials and processes are related to weight saving considerations and the high-pressure hydrogen environment. Special problems and their solution in the case of various engine components are discussed, giving attention to the oxidizer preburner, the high pressure oxidizer turbopump, and the heat exchanger.
Thin walls of 304L stainless steel were fabricated by wire-arc additive manufacturing (WAAM) followed by post build thermomechanical processing to modify the as built microstructure and properties. The walls were made using a high-deposition-rate robotically controlled gas-metal arc welding system and were characterized using optical microscopy and tensile tested for mechanical properties. Post processing consisted of mechanical rolling the walls to 25% and 40% strains, followed by annealing at 1050°C to demonstrate a wide range of properties. Results show that WAAM can be used to build custom sized semi-finished parts or blanks that can later be thermomechanically processed to increase strength and ductility through recrystallization of the as built microstructure, and/or processed into desired shapes with improved mechanical properties.
Cooling rates effect on microstructure and strength of gas tungsten arc welds of aluminum alloy
Porosity effects on mechanical properties of Al alloy gas tungsten arc welds, noting strength loss proportional to cross sectional area loss