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Trailing shield ensures layer of inert gas covers hot, newly formed bead between two tubes or pipes joined by plasma arc welding. Inert gas protects weld bead from oxidation by air until cooler and less vulnerable to oxidation. Intended for use on nickel-base alloy pipes, on which weld beads remain hot enough to oxidize after primary inert-gas purge from welding-torch cup has passed.
The development of a model for prediction of heat sink effects associated with the Variable Polarity Plasma Arc (VPPA) Welding Process is discussed. The long term goal of this modeling is to provide means for assessing potential heat sink effects and, eventually, to provide indications as to changes in the welding process that could be used to compensate for these effects and maintain the desired weld quality. In addition to the development of a theoretical model, a brief experimental investigation was conducted to demonstrate heat sink effects and to provide an indication of the accuracy of the model.
A composite flexible blanket insulation (CFBI) system considered for use as a thermal protection system for space vehicles is described. This flexible composite insulation system consists of an outer layer of silicon carbide fabric, followed by alumina mat insulation, and alternating layers of aluminized polyimide film and aluminoborosilicate scrim fabric. A potential application of this composite insulation would be as a thermal protection system for the aerobrake of the aeroassist space transfer vehicle (ASTV). It would also apply to other space vehicles subject to high convective and radiative heating during atmospheric entry. The thermal performance of this composite insulation as exposed to a simulated atmospheric entry environment in a plasma arc test facility is described. Other thermophysical properties which affect the thermal response of this composite insulation is included. It shows that this composite insulation is effective as a thermal protection system at total heating rates up to 30.6 W/sq cm.
Hardware development of the Shuttle Entry Data System (SEADS) is described. The system consists of an array of fourteen pressure ports, installed in an Orbiter nose cap, which, when coupled with existing fuselage mounted static pressure ports permits computation of entry flight parameters. Elements of the system that are described include the following: (1) penetration assemblies to place pressure port openings at the surface of the nose cap; (2) pressure tubes to transmit the surface pressure to transducers; (3) support posts or manifolds to provide support for, and reduce the length of, the individual pressure tubes; (4) insulation for the manifolds; and (5) a SEADS nose cap. Design, analyses, and tests to develop and certify design for flight are described. Specific tests include plasma arc exposure, radiant thermal, vibration, and structural. Volume one summarizes highlights of the program, particularly as they relate to the final design of SEADS. Volume two summarizes all of the Vought responsible activities in essentially a chronological order.
Hardware development of the Shuttle Entry Air Data System (SEADS) is described. The system consists of an array of fourteen pressure ports, installed in an Orbiter nose cap, which, when coupled with existing fuselage mounted static pressure ports permits computation of entry flight parameters. Elements of the system that are described include the following: (1) penetration assemblies to place pressure port openings at the surface of the nose cap; (2) pressure tubes to transmit the surface pressure to transducers; (3) support posts or manifolds to provide support for, and reduce the length of, the individual pressure tubes; (4) insulation for the manifolds; and (5) a SEADS nose cap. Design, analyses, and tests to develop and certify design for flight are described. Specific tests included plasma arc exposure, radiant thermal, vibration, and structural. Volume one summarizes highlights of the program, particularly as they relate to the final design of SEADS. Volume two summarizes all of the Vought responsible activities in essentially a chronological order.
Theoretical and experimental studies of heat-tranfer in a space environment are discussed in reviews and reports. Topics addressed include a small-scale two-phase thermosiphon to cool high-power electronics, a low-pressure-drop heat exchanger with integral heat pipe, an analysis of the thermal performance of heat-pipe radiators, measurements of temperature and concentration fields in a rectangular heat pipe, and a simplified aerothermal heating method for axisymmetric blunt bodies. Consideration is given to entropy production in a shock wave, bubble-slug transition in a two-phase liquid-gas flow under microgravity, plasma arc welding under normal and zero gravity, the Microgravity Thaw Experiment, the flow of a thin film on stationary and rotating disks, an advanced ceramic fabric body-mounted radiator for Space Station Freedom phase 0 design, and lunar radiators with specular reflectors.
The application is described of a weld programming algorithm for vertical-up welding, which is frequently desired for variable polarity plasma arc welding (VPPAW). The Basic algorithm performs three tasks simultaneously: control of the robotic mechanism so that proper torch motion is achieved while minimizing the sum-of-squares of joint displacement; control of the torch while the part is maintained in a desirable orientation; and control of the wire feed mechanism location with respect to the moving welding torch. Also presented is a modification of this algorithm which permits it to be used for vertical-up welding. The details of this modification are discussed and simulation examples are provided for illustration and verification.
Described here is the thermal performance of rigid and flexible thermal protection systems considered for potential use in future Aeroassist Space Transfer Vehicles. The thermal response of these materials subjected to aeroconvective heating from a plasma arc is described. Properties that were measured included the thermal conductivity of both rigid and flexible insulations at various temperatures and pressures and the emissivity of the fabrics used in the flexible insulations. The results from computerized thermal analysis models describing the thermal response of these materials subjected to flight conditions are included.
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.
Fully automated variable-polarity plasma arc VPPA welding system developed at Marshall Space Flight Center. System eliminates defects caused by human error. Integrates many sensors with mathematical model of the weld and computer-controlled welding equipment. Sensors provide real-time information on geometry of weld bead, location of weld joint, and wire-feed entry. Mathematical model relates geometry of weld to critical parameters of welding process.
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.
The instrument described in this manual was developed at the University of Texas at El Paso under contract from the National Aeronautics and Space Administration Marshall Space Flight Center. The instrument has been used to detect hydrogen in the shielding gas of Variable Polarity Plasma Arc (VPPA) welds at concentrations of less than 100 ppm. The instrument makes measurements in real time during the welding operation and provides the operator with an easily readable graphic display of the present level of hydrogen in the arc as well as the level of hydrogen over the past approximately five minutes. In this way the welder can not only tell if the present level of hydrogen is excessive, but can see what changes in weld parameters have done to the level of hydrogen. The welder can set the level of hydrogen that is considered critical and the instrument display will indicate when that level has been exceeded. All detection is from the torch side. All needed equipment is supplied by the developer except for an IBM PC compatible computer which must be supplied by the user. Source code is supplied in this manual so that the user can modify the control program as desired.
Titanium aluminides and titanium alloys are candidate materials for use in hot structure and heat-shield components of hypersonic vehicles because of their good strength-to-weight characteristics at elevated temperature. However, in order to utilize their maximum temperature capability, they must be coated to resist oxidation and to have a high total remittance. Also, surface catalysis for recombination of dissociated species in the aerodynamic boundary layer must be minimized. Very thin chemical vapor deposition (CVD) coatings are attractive candidates for this application because of durability and very light weight. To demonstrate this concept, coatings of boron-silicon and aluminum-boron-silicon compositions were applied to the titanium-aluminides alpha2 (Ti-14Al-21Nb), super-alpha2 (Ti-14Al-23-Nb-2V), and gamma (Ti-33Al-6Nb-1Ta) and to the titanium alloy beta-21S (Ti-15Mo-3Al-3Nb-0.2Si). Coated specimens of each alloy were subjected to a set of simulated hypersonic vehicle environmental tests to determine their properties of oxidation resistance, surface catalysis, radiative emittance, and thermal shock resistance. Surface catalysis results should be viewed as relative performance only of the several coating-alloy combinations tested under the specific environmental conditions of the LaRC Hypersonic Materials Environmental Test System (HYMETS) arc-plasma-heated hypersonic wind tunnel. Tests were also conducted to evaluate the hydrogen transport properties of the coatings and any effects of the coating processing itself on fatigue life of the base alloys. Results are presented for three types of coatings, which are as follows: (1) a single layer boron silicon coating, (2) a single layer aluminum-boron-silicon coating, and (3) a multilayer coating consisting of an aluminum-boron-silicon sublayer with a boron-silicon outer layer.
A composite flexible blanket insulation (CFBI) system considered for use as a thermal protection system for space vehicles is described. This flexible composite insulation system consists of an outer layer of silicon carbide fabric, followed by alumina mat insulation, and alternating layers of aluminized polyimide film and aluminoborosilicate scrim fabric. A potential application of this composite insulation would be as a thermal protection system for the aerobrake of the aeroassist space transfer vehicle (ASTV). It would also apply to other space vehicles subject to high convective and radiative heating during atmospheric entry. The thermal performance of this composite insulation as exposed to a simulated atmospheric entry environment in a plasma arc test facility is described. Other thermophysical properties which affect the thermal response of this composite insulation is included. It shows that this composite insulation is effective as a thermal protection system at total heating rates up to 30.6 W/sq cm.
A fully automated welding system, which can operate totally independent of human intervention, is currently unavailable in the welding industry. Development of the Marshall Automated Weld System (MAWS) has been undertaken to fill this void. The system will enable application of statistical process control practices to assure weld quality prior to post weld nondestructive testing. The Variable Polarity Plasma Arc (VPPA) welding process has been baselined for MAWS because it has eliminated process related defects in the welding of the Space Shuttle External Tank. The few remaining weld defects occurring on the tank can be associated with human error. The system integrates multiple sensors (providing real time information on weld bead geometry, weld joint location, wirefeed entry, and inert gas quality) with a weld model (describing weld geometry in relation to critical parameters) and computer-controlled VPPA weld equipment. This system is designed to provide real-time, closed-loop control of the weld as it is being made.
The Advanced Solid Rocket Motor (ASRM) case design aimed at achieving a safer and more reliable solid rocket motor for the Space Shuttle system is considered. The ASRM case has a 150.0 inch diameter, three equal length segment, and 9Ni-4CO-0.3C steel alloy. The major design features include bolted casebolted case joints which close during pressurization, plasma arc welded factory joints, integral stiffener for splash down and recovery, and integral External Tank attachment rings. Each mechanical joint has redundant and verifiable o-ring seals.
Reusable, oxidation protected reinforced carbon carbon (RCC) has been successfully flown on forty Shuttle Orbiter flights. Thermal testing of the silicon carbide coated, reinforced carbon-carbon to determine its oxidation characteristics has been performed in both radiant and convective (plasma arc jet) heating test facilities. Subsurface oxidation of the RCC substrate as a result of oxygen penetrating micro cracks (fizzures) in the coating was characterized as a function of temperature and pressure for both convective and radiant environments. High temperature testing was performed to establish coating recession for over-temperature flight conditions experienced on abort trajectories. Suggested methods for using these test data to establish multi-mission reuse (i.e., mission life) and single mission limits are presented.