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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Mechanical properties of fusion welded ceramics in the $\mathrm{SiC-ZrB}$ 2 and $\mathrm{SiC-ZrB}$ 2 -$\mathrm{ZrC}$ systems

Mechanical properties of welded SiC-ZrB 2 and SiC-ZrB 2 -ZrC ceramics were measured up to 1700 °C. Commercial powders were hot pressed, machined into coupons, and preheated to 1600 °C before joining the ceramics using either tungsten inert gas welding or plasma arc welding. Toughness of the parent materials was 3–4 MPa*m 1/2 which decreased after welding to 2–2.5 MPa*m 1/2 . Strength of the SiC-ZrB 2 -ZrC parent material was ~700 MPa at 25 °C, ~300 MPa at 1700 °C, and retained 40–60% of this strength once welded. Strength of the SiC-ZrB2 parent material was ~600 MPa at 25 °C and 1700 °C and retained 20–30% of this strength once welded. Griffith analysis indicated that the strength in the parent materials was controlled by the size of SiC clusters while strength of welds was controlled by the size of pores in fusion zones. Therefore, removal of pores in produced fusion zones should be investigated to improve strength of future ceramic welds.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Spatial mapping of the localized corrosion behavior of a magnesium alloy AZ31B tungsten inert gas weld

Sections of a magnesium alloy, AZ31B, joined with tungsten inert gas (TIG) welding, were examined with scanning electrochemical microscopy (SECM) and scanning Kelvin probe force microscopy (SKPFM) to investigate corrosion mechanisms by correlating observed corrosion behavior with weld-affected microstructural variations. Insight into the changing nature of the galvanic couples between weld zones and at localized microgalvanic sites were investigated using SECM and SKPFM to map both electrochemically active regions and Volta potential differences across the weld-affected zones. The formation of an Al-Zn solidification network in the fusion zone (FZ) at and near the TIG weld epicenter differs from the outer heat-affected zone (HAZ), where intermetallic particles (IMPs) are the notable secondary phase from the magnesium matrix. These microstructures were mapped with SKPFM before and after brief exposure to a salt solution, revealing micro-galvanic couples as the main driving force to corrosion initiation and propagation within each zone. The IMPs and Al-Zn solidification network act as strong cathodes and govern the corrosion processes. The galvanic coupling and evolution of the intrinsic corrosion behavior between the weld zones is explained by monitoring the hydrogen evolution reaction (HER) with SECM over time. Anodically induced cathodic activation is confirmed for this welded material, as micro-galvanic couples between microstructural features are found to transition over time to broad electrochemically active areas within the weld-affected zones, resulting in polarity reversal as time of exposure proceeds.

Anodically induced cathodic activation↗
DOE OSTI2020

Microstructure and strength of a thick-section gas-tungsten arc weld in cast Haynes® 282® alloy

A 50-mm deep gas tungsten arc weld was made with matching filler metal in cast Haynes 282 alloy. The narrow gap joint was filled with 104 weld beads. The weld deposit was of high quality with no visible indications of physical defects. The weld heat-affected zone was characterized by microcracking and localized recrystallization. Hardness testing showed that a softened region in the as-welded heat-affected zone was nearly eliminated by post-weld heat treatment. Tensile testing up to 816°C showed that cross-weld specimen strengths were about 80% of the yield strength of the original cast base metal. The rupture strengths of cross-weld specimens are within 20% of wrought base metal reference data.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hardness Prediction by Incorporating Heat Transfer and Molten Pool Fluid Flow in a Multi-pass, Multi-layer Weld for Onsite Repair of Grade 91 steel

Introduction: In the current fleet of fossil-fired power plants, creep strength enhanced ferritic steels (CSEF) are used to sustain the harsh service conditions. Enhanced properties of Grade 91 steel result from tempered martensite with a fine distribution of MX and M23C6 carbides. Grade 91 steel is subjected to onsite welding repair to remedy their degradation due to extreme service condition. Knowledge of weld repairability of these steels, such as as-welded hardness distribution, is essential to establishing sound repair procedures. Experimental trial and error tests can consume a lot of time as many welding variables need to be studied. For numerical modelling, most of the multi-pass multi-layer models are based on finite element method, which are limited to solve the heat conduction equation and ignore convective heat transfer due to melt flow. Moreover, the mesh has to be pre-built based on a known or assumed weld cross-section geometry. These finite element based models thus have limited predictive capability as defects are not considered and nugget size are pre-assumed. This research aims at developing a thermal and microstructure evolution model incorporating molten pool dynamics in a multi-pass multi-layer material deposition to predict the as-welded hardness distribution. Technical Approach: All the thermal, physical, and metallurgical properties of Grade 91 as a function of temperature are collected from the literature and inputted into the thermo-fluid model based on Flow-3D, a computational fluid dynamics software. A multi-pass, multi-layer material deposition is simulated where the melting of filler wire into the molten pool is directly considered based on the volume of fluid (VOF) method. The flow behaviour of the molten pool is used to understand the formation of deposition geometry and defects. The temperature profiles during the multi-pass, multi-layer welding are calculated. The results computed using the new model are compared against the experimental data of fusion zone geometry and thermal cycles. Hardness prediction in the heat-affected zone (HAZ) are made using Johnson-Mehl-Avrami (JMA) equation for solid-state phase transformation kinetics. The JMA parameters are extracted from the experimental data available in the literature. For comparison, a standard finite element heat conduction model is also developed to predict the thermal cycles and hardness distribution in the multi-pass, multi-layer weld. Expected Result: Results obtained using the molten pool dynamic simulation versus the finite element heat conduction model are compared. Specifically, the effects of convective heat transfer on the accuracy of the calculated thermal history, bead shape and size, and HAZ hardness distribution are examined.

Modeling, Grade 91 steel, Multi-pass multi-layer d↗
NASA NTRS1971

Study program of NASA/GSFC weld quality monitor system

The Weld Quality Monitor has provided online control through the application of linear transducers. The electronic systems must be upgraded to increase confidence level required in production. The Weld Quality Monitor has been used with a recent model solid state power supply to evaluate ability to differentiate between sound and defective weld joints. The Weld Quality Monitor has been evaluated on Dumet and Kovar to interconnect materials Nickel and Alloy 180 in weld joints used on microelectronic module fabrication. Distinct separation was achieved between low strength welds and sound welds by the Quality Monitor. Evaluation performed indicates a drift level at less than 2 percent on a series of 50 consecutive welds. Operation under shop conditions identified need for controlled electrode impact. This was achieved with pneumatic actuation.

Hutchinson, W. R.↗
NASA NTRS1973

Study of gas tungsten arc welding procedures for tantalum alloy T-111 (Ta-8 W-2Hf) plate

Methods of eliminating or reducing underbread cracking in multipass GTA welds in thick T-111 plate were studied. Single V butt welds prepared using experimental filler metal compositions and standard weld procedures resulted in only moderate success in reducing underbread cracking. Subsequent procedural changes incorporating manual welding, slower weld speeds, and three or fewer fill passes resulted in crack-free single V welds only when the filler metal was free of hafnium. The double V joint design with successive fill passes on opposite sides of the joint produced excellent welds. The quality of each weld was determined metallographically since the cracking, when present, was very slight and undetectable using standard NDT techniques. Tensile and bend tests were performed on selected weldments. The inherent filler metal strength and the joint geometry determined the strength of the weldment. Hardness and electron beam microprobe traverses were made on selected specimens with the result that significant filler metal-base metal dilution as well as hafnium segregation was detected. A tentative explanation of T-111 plate underbread cracking is presented based on the intrinsic effects of hafnium in the weldment.

Gold, R. E.↗
NASA NTRS1974

Polyimide weld bonding for titanium alloy joints

Two weld bonding processes were developed for joining titanium alloy; one process utilizes a weld-through technique and the other a capillary-flow technique. The adhesive used for the weld-through process is similar to the P4/A5F system. A new polyimide laminating resin, BFBI/BMPM, was used in the capillary-flow process. Static property information was generated for weld-bonded joints over the temperature range of 219 K (-65 F) to 561 K (+550 F) and fatigue strength information was generated at room temperature. Significant improvement in fatigue strength was demonstrated for weld-bonded joints over spot-welded joints. A demonstration was made of the applicability of the weld-through weld-bonding process for fabricating stringer stiffened skin panels.

Vaughan, R. W.↗
NASA NTRS1978

Linear dimension establishes weld integrity

Study finds that when automatic in-place tube-welding head is used to butt-weld two stainless-steel tubes together, welding process can be made so reliable that when weld exceeds a certain minimum dimension, penetration of weld can be assumed to be complete. Detailed procedure for tube welding considers effects of arc gap, shielding gas, welding speed, and other parameters related to weld reliability.

Lewis, J. C.↗
NASA NTRS1982

Welding Research

Welding fabrication and welding processes were studied. The following research projects are reported: (1) welding fabrication; (2) residual stresses and distortion in structural weldments in high strength steels; (3) improvement of reliability of welding by in process sensing and control (development of smart welding machines for girth welding of pipes); (4) development of fully automated and integrated welding systems for marine applications; (5) advancement of welding technology; (6) research on metal working by high power laser (7) flux development; (8) heat and fluid flow; (9) mechanical properties developments.

Source record↗
NASA NTRS1982

Evaluation of electrode shape and nondestructive evaluation method for welded solar cell interconnects

Resistance welds of solar cell interconnect tabs were evaluated. Both copper-silver and silver-silver welds were made with various heat inputs and weld durations. Parallel gap and annular gap weld electrode designs were used. The welds were analyzed by light microscope, electron microprobe and scanning laser acoustic microscope. These analyses showed the size and shape of the weld, the relationship between the acoustic micrographs, the visible electrode footprint, and the effect of electrode misalignment. The effect of weld heat input on weld microstructure was also shown.

Baraona, C. R.↗
NASA NTRS1985

NASA welding assessment program

A program was conducted to demonstrate the cycle life capability of welded solar cell modules relative to a soldered solar cell module in a simulated low earth orbit thermal environment. A total of five 18-cell welded (parallel gap resistance welding) modules, three 18-cell soldered modules, and eighteen single cell samples were fabricated using 2 x 4 cm silicon solar cells from ASEC, fused silica cover glass from OCLI, silver plated Invar interconnectors, DC 93-500 adhesive, and Kapton-Kevlar-Kapton flexible substrate material. Zero degree pull strength ranged from 2.4 to 5.7 lbs for front welded contacts (40 samples), and 3.5 to 6.2 lbs for back welded contacts (40 samples). Solar cell cross sections show solid state welding on both front and rear contacts. The 18-cell welded modules have a specific power of 124 W/kg and an area power density of 142 W/sq m (both at 28 C). Three welded and one soldered module were thermal cycle tested in a thermal vacuum chamber simulating a low earth orbit thermal environment.

Patterson, R. E.↗
NASA NTRS1985

Signal Analysis of Gas Tungsten Arc Welds

Gas tungsten arc welding is a process in which the input parameters such as current, voltage and travel speed, can be easily controlled and/or monitored. However, weld quality is not solely a function of these parameters. An adaptive method of observing weld quality is desired to improve weld quality assurance. The use of dynamic electrical properties of the welding arc as a weld quality monitor was studied. The electrical properties of the arc are characterized by the current voltage transfer function. The hardware and software necessary to collect the data at a maximum rate of 45 kHz and to allow the off-line processing of this data are tested. The optimum input current waveform is determined. Bead-on-plate welds to observe such characteristics of the weld as the fundamental frequency of the puddle are studied. Future work is planned to observe changes of the arc response with changes in joint geometry, base metal chemistry, and shielding gas composition are discussed.

Eagar, T. W.↗
NASA NTRS1986

On the determination of the origin of linear anomaly in the macrostructure of VPPA welded 2219-T87 aluminum alloy: Preliminary report

The cause and significance of the weld radiograph enigma, which is a linear anomaly in the features of the X-ray film is examined. By observing features on available radiographs and in studying published reports of similar features, it was possible to conclude that there are many manifestations of the enigma, and that they are all specific features of fine structure in radiographs due to natural processes connected with welding and to specific X-ray absorption and diffraction phenomena. These processes include the thermal distribution and liquid metal flow in welding, the development of microstructure, morphology, second phase particles and porosity due to the solidification process, and to the pattern of residual stresses after the weld metal has cooled to the ambient temperature. Microdensitometer traces were made across weld radiographs of standard enigmatic types. Similar patterns were produced by computer simulation. These show that the enigma is a relatively low contrast feature compared to real weld defects, such as undercuts or centerline cracks. The enigma can be distinguished from weld defects by these microdensitometer traces. The enigma effect on weld properties is not known but is expected to be minor.

Jemian, W. A.↗
NASA NTRS1986

On the determination of the origin of linear anomaly in the macrostructure of VPPA welded 2219-T87 aluminum alloy

The objective was to determine the cause and significance of the weld radiograph enigma, which is a linear anomaly in the features of the X-ray film. By observing features on available radiographs and in studying published reports of similar features it was possible to conclude that there are many manifestations of the enigma, and that they are all specific features of fine structure in radiographs due to natural processes connected with welding and to specific X-ray absorption and diffraction phenomena. These processes include the thermal distribution and liquid metal flow in welding, the development of microstructure, morpohology, second phase particles and porosity due to the solidification process and to the pattern of residual stresses after the weld metal has cooled to the ambient temperature. Microdensitometer traces were made across weld radiographs of standard and enigmatic types. Similar patterns were produced by computer simulation. These show that the enigma is a relatively low contrast feature compared to real weld defects, such as undercuts or centerline cracks. The enigma can be distinguished from weld defects by these microdensitometer traces. The enigma effect on weld properties is not known but is expected to be minor.

Jemian, W. A.↗
NASA NTRS1986

Development of sensor augmented robotic weld systems for aerospace propulsion system fabrication

In order to meet stringent performance goals for power and reuseability, the Space Shuttle Main Engine was designed with many complex, difficult welded joints that provide maximum strength and minimum weight. To this end, the SSME requires 370 meters of welded joints. Automation of some welds has improved welding productivity significantly over manual welding. Application has previously been limited by accessibility constraints, requirements for complex process control, low production volumes, high part variability, and stringent quality requirements. Development of robots for welding in this application requires that a unique set of constraints be addressed. This paper shows how robotic welding can enhance production of aerospace components by addressing their specific requirements. A development program at the Marshall Space Flight Center combining industrial robots with state-of-the-art sensor systems and computer simulation is providing technology for the automation of welds in Space Shuttle Main Engine production.

Jones, C. S.↗
NASA NTRS1985

Remotely manipulated and autonomous robotic welding fabrication in space

The results of a NASA sponsored study, performed in order to establish the feasibility of remotely manipulated or unmanned welding fabrication systems for space construction, are presented. Possible space welding fabrication tasks and operational modes are classified and the capabilities and limitations of human operators and machines are outlined. Human performance in remote welding tasks was experimentally tested under the sensing and actuation constraints imposed by remote manipulation in outer space environments. Proposals for the development of space welding technology are made and necessary future R&D efforts are identified. The development of improved visual sensing strategies and computer encoding of the human welding engineering expertise are identified as essential, both for human operator assistance and for autonomous operation in all phases of welding fabrication. Novel uses of machine vision for the determination of the weld joint and bead geometry are proposed, and a prototype of a rule-based expert system is described for the interpretation of the visually detected weld features and defects.

Agapakis, J. E.↗
NASA NTRS1988

The keyhole region in VPPA welds

The morphology and properties of the Variable Polarity Plasma Arc (VPPA) weld composite zone are intimately related to the physical processes associated with the keyhole. The effects of microsegregation and transient weld stress on macrosegregation in the weld tool are examined. In addition the electrical character of straight and reverse polarity portions of the arc cycle were characterized. The results of the former study indicate that alloy 2219 is weldable because large liquid volumes are available during latter stages of weld solidification. Strains in the pool region, acting in conjunction with weld microsegregation can produce macrosegregation great enough to produce radiographic contrast effects in welds. Mechanisms of surface copper enrichment were identified. The latter study has demonstrated that increased heat is delivered to workpieces if the reverse polarity proportion of the weld cycle is increased. Current in the straight polarity portion of the welding cycle increased as the reverse cycle proportion increased. Voltage during reverse polarity segments is large.

Walsh, Daniel W.↗
NASA NTRS1989

Onorbit electron beam welding experiment definition

The proposed experiment design calls for six panels to be welded, each having unique characteristics selected to yield specific results and information. The experiment is completely automated and the concept necessitated the design of a new, miniaturized, self-contained electron beam (EB) welding system, for which purpose a separate IR and D was funded by the contractor, Martin Marietta Corporation. Since future tasks beyond the proposed experiment might call for astronauts to perform hand-held EB gun repairs or for the gun to be interfaced with a dexterous robot such as the planned flight telerobotic servicer (FTS), the EB gun is designed to be dismountable from the automated system. In the experiment design, two separate, identical sets of weld panels will be welded, one on earth in a vacuum chamber and the other onorbit in the aft cargo bay of an orbiter. Since the main objective of the experiment is to demonstrate that high quality welds can be achieved under onorbit conditions, the welds produced will be subjected to a wide range of discriminating non-destructive Q.C. procedures and destructive physical tests. However, advantage will be taken of the availability of a fairly large quantity of welded material in the two series of welded specimens to widen the circle of investigative talent by providing material to academic and scientific institutions for examination.

William H. Hooper↗