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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

Analysis of ripple formation in single crystal spot welds

Stationary spot welds have been made at the (001) surface of Fe-l5%Ni-15%Cr single crystals using a Gas Tungsten Arc (GTA). On the top surface of the spot welds, very regular and concentric ripples were observed after solidification by differential interference color microscopy. Their height (typically 1--5 micrometers and spacing, typically approximately 60 micrometers) decreased with the radius of the pool. These ripples were successfully accounted for in terms of capillary-wave theory using the fundamental mode frequency f(sub 0) given by the first zero of the zero-order Bessel function. The spacing d between the ripples was then equated to v(sub s)/f(sub 0), where v(sub s) is the solidification rate. From the measured ripple spacing, the velocity of the pool was deduced as a function of the radius, and this velocity was in good agreement with the results of a heat-flow simulation.

Rappaz, M.↗
NASA NTRS1999

Stability of Full Penetration, Flat Position Weld Pools

The dynamics of the dropthrough distance of a full penetration, flat position weld pool is described. Close to incipient root side penetration the dropthrough is metastable, so that a small drop in power can cause a loss of penetration if not followed soon enough by a compensating rise in power. The SPA (Soft Plasma Arc) process with higher pressure on top of the weld pool loses penetration more quickly than the GTA (Gas Tungsten Arc) process. 2195 aluminum-lithium alloy with a lower surface tension loses penetration more quickly than 2219 aluminum alloy. An instance of loss of penetration of a SPA weld in 2195 aluminum-lithium alloy is discussed in the light of the model.

Nunes, Arthur C., Jr.↗
NASA NTRS1989

Optical inspection of space-propulsion components using an injection seeded Nd:YAG laser system

A dual-beam, injection-seeded, Nd:YAG laser has been demonstrated for detecting structural defects. This demonstration was part of an on-going project to use dual-reference-beam holographic interferometry to inspect space propulsion components for cracks, structural failures, structural changes, and gas leaks. Potential subjects for inspection include welds, duct work, casings, turbopumps, blades, composites, and ceramics. The maximum dimension of an inspected area ranges from a few centimeters to a meter. The entire optical inspection system is now ready for a demonstration application.

Decker, Arthur J.↗
NASA NTRS1996

Cyclically controlled welding purge chamber

An arrangement for butt-welding cylindrical sections of large, thin-wall tanks includes a rotatable mandrel with side-by-side sets of radial position adjusters. Each set of adjusters bears on one of the tank sections adjacent the seam, to prevent the sections from sagging out-of-round. The mandrel rotates relative to the welder, so that a continuous seam is formed. A purge chamber is fixed in position behind the seam at the weld head, and is flushed with inert gas. The purge chamber includes a two-sided structure which is contiguous with the cylindrical sections and a circumferential vane to form an open-ended tube-like structure, through which the radial position adjusters pass as the mandrel and cylindrical workpiece sections rotate. The tube-like structure is formed into a chamber by a plurality of movable gates which are controlled to maintain a seal while allowing adjusters to progress through the purge chamber.

Gallagher, Robert L.↗
DOE OSTI2022

ELECTRIC FIELD-ASSISTED DIFFUSION WELDING TO FABRICATE ALLOY 617 COMPACT HEAT EXCHANGERS

Compact heat exchangers are of interest for a number of applications including advanced reactors. Alloy 617 is one of the top candidate materials for the gas-cooled reactor intermediate heat exchanger. Previous endeavors to diffusion weld Alloy 617 utilized hot pressing (HP). It was reported that grain boundary migration across the interface was hindered by extensive precipitation. Bonds of this nature have been observed to reduce the elevated-temperature mechanical properties compared to the wrought-product form. It was hypothesized that the electric current applied during electric-field-assisted sintering (EFAS) can overcome these challenges, resulting in improved diffusion welding (DW). This study investigated DW of Alloy 617 via EFAS. Stacks composed of three sheets that were 20 mm in diameter were welded using EFAS. Specimens were welded with an applied electric current, a pressure of 30 MPa, hold time of 30 min, and temperatures of 1050°C, 1100°C, and 1150°C. DW using HP as the zero-current analog of EFAS was also performed at the most promising EFAS conditions. Results revealed that both the applied electric current and temperature played a key role in precipitation and grain boundary migration in diffusion-welded Alloy 617. Precipitates were observed at the interface of the hot-pressed samples which limited grain boundary migration. Electric current was found to prevent precipitate formation along the interface at 1150°C. The electric current coupled with a temperature of 1150°C during EFAS resulted in significant grain boundary migration across the interface.

36 - MATERIALS SCIENCE↗
NASA NTRS1972

Fracture and crack growth resistance studies of 304 stainless steel weldments relating to retesting of cryogenic vessels

Fracture and crack growth resistance characteristics of 304 stainless steel alloy weldments as relating to retesting of cryogenic vessels were examined. Welding procedures were typical of those used in full scale vessel fabrication. Fracture resistance survey tests were conducted in room temperature air, liquid nitrogen and liquid hydrogen. In air, both surface-flawed and center-cracked panels containing cracks in weld metal, fusion line, heat-affected zone, or parent metal were tested. In liquid nitrogen and liquid hydrogen, tests were conducted using center-cracked panels containing weld centerline cracks. Load-unload, sustained load, and cyclic load tests were performed in air or hydrogen gas, liquid nitrogen, and liquid hydrogen using surface-flawed specimens containing weld centerline cracks. Results were used to evaluate the effectiveness of periodic proof overloads in assuring safe and reliable operation of over-the-road cryogenic dewars.

Hall, L. R.↗
NASA NTRS1992

Compact Through-The-Torch Vision System

Changes in gas/tungsten-arc welding torch equipped with through-the-torch vision system make it smaller and more resistant to welding environment. Vision subsystem produces image of higher quality, flow of gas enhanced, and parts replaced quicker and easier. Coaxial series of lenses and optical components provides overhead view of joint and weld puddle real-time control. Designed around miniature high-resolution video camera. Smaller size enables torch to weld joints formerly inaccessible.

Gilbert, Jeffrey L.↗
DOE OSTI2018

Thermal Model of the AGR-5/6/7 Experiment

Several fuel and material irradiation experiments have been planned for the U.S. Department of Energy Advanced Gas Reactor Fuel Development and Qualification Program, which supports the development and qualification of tristructural isotropic (TRISO) coated particle fuel for use in high-temperature gas-cooled reactors. The goals of these experiments are to provide irradiation performance data to support fuel process development, qualify fuel for normal operating conditions, support development of fuel performance models and codes, and provide irradiated fuel and materials for post-irradiation examination and safety testing. Originally planned and named as separate fuel experiments, but subsequently combined into a single test train, AGR-5/6/7 will test low-enriched uranium oxycarbide (UCO – a heterogeneous mixture of uranium oxide and uranium carbide) TRISO fuel. The AGR-5/6 portion of the experiment will provide data to support qualification of the selected reference fuel design, while the AGR-7 portion will serve as a margin test, irradiating the fuel beyond normal operating conditions. A thermal finite element model has been created for the five capsules comprising the AGR-5/6/7 experiment. Heat rates from a physics analysis are imported into the model along with fast neutron fluence. Graphite shrinkage due to the fast neutron fluence is incorporated into the model. Gas gaps change as a function of fast neutron fluence. Radiation heat transfer is a major contributor in this model. This is a large model with more than 1 million finite element brick elements. More than 150 different parts are modeled in the finite element model and communicate with each other from a heat transfer sense. More than 50 thermocouples are used in the experiment and are compared to actual measurements. The experiment is composed of five separate stainless steel capsules all welded together. Each capsule has its own Helium/.Neon gas mixture to help control the temperature of the capsule.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1993

Plasma arc welding repair of space flight hardware

Repair and refurbishment of flight and test hardware can extend the useful life of very expensive components. A technique to weld repair the main combustion chamber of space shuttle main engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloyZ, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloyZ while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

Hoffman, David S.↗
NASA NTRS1995

Vacuum vapor deposition

A method and apparatus is described for vapor deposition of a thin metallic film utilizing an ionized gas arc directed onto a source material spaced from a substrate to be coated in a substantial vacuum while providing a pressure differential between the source and the substrate so that, as a portion of the source is vaporized, the vapors are carried to the substrate. The apparatus includes a modified tungsten arc welding torch having a hollow electrode through which a gas, preferably inert, flows and an arc is struck between the electrode and the source. The torch, source, and substrate are confined within a chamber within which a vacuum is drawn. When the arc is struck, a portion of the source is vaporized and the vapors flow rapidly toward the substrate. A reflecting shield is positioned about the torch above the electrode and the source to ensure that the arc is struck between the electrode and the source at startup. The electrode and the source may be confined within a vapor guide housing having a duct opening toward the substrate for directing the vapors onto the substrate.

Poorman, Richard M.↗
NASA NTRS1978

Development and fabrication of a diffusion welded Columbium alloy heat exchanger

A Mini Brayton space power generation system required the development of a Columbium alloy heat exchanger to transfer heat from a radioisotope heat source to a He/Xe working fluid. A light-weight design featured the simultaneous diffusion welding of 148 longitudinal fins in an annular heat exchanger about 9-1/2 in. in diameter, 13-1/2 in. in length and 1/4 in. in radial thickness. To complete the heat exchanger, additional gas ducting elements and attachment supports were added by GTA welding in a vacuum-purged inert atmosphere welding chamber. The development required the modification of an existing large size hot isostatic press to achieve HIP capabilities of 2800 F and 10,000 psi for at least 3 hr. Excellent diffusion welds were achieved in a high-quality component which met all system requirements.

Zimmerman, W. F.↗
NASA NTRS2011

Conduit purging device and method

A device for purging gas comprises a conduit assembly defining an interior volume. The conduit assembly comprises a first conduit portion having an open first end and an open second end and a second conduit portion having an open first end and a closed second end. The open second end of the first conduit portion is disposed proximate to the open first end of the second conduit portion to define a weld region. The device further comprises a supply element supplying a gas to the interior volume at a substantially constant rate and a vent element venting the gas from the interior volume at a rate that maintains the gas in the interior volume within a pressure range suitable to hold a weld bead in the weld region in equilibrium during formation of a weld to join the first conduit portion and the second conduit portion.

Wilks, Michael T.↗
NASA NTRS1983

Swirl Diffuser

Gas diffuser, based on swirling flow, dissipates incoming gas velocity in relatively short distance. Pinwheel nozzle welded to end of inlet pipe creates swirling flow. Diffuser esentially open pipe with pinwheel nozzle, pressure drop in diffuser almost same as open pipe. Applications include fuel burners in room inlets for heating and air-conditioning, and carburetors for internal-combustion engines.

Simon, W. E.↗
NASA NTRS1990

Characteristics and performance of the variable polarity plasma arc welding process used in the Space Shuttle external tank

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. Flow profiles and power distribution of argon plasma gas as a working fluid to produce plasma arc jet in the VPPA welding process was analyzed. Major loss of heat transfer for flow through the nozzle is convective heat transfer; for the plasma jet flow between the outlet of the nozzle and workpiece is radiative heat transfer; and for the flow through the keyhole of the workpiece is convective heat transfer. The majority of the power absorbed by the keyhole of the workpiece is used for melting the solid metal workpiece into a molten metallic puddle. The crown and root widths and the crown and root heights can be predicted. An algorithm for promoting automatic control of flow parameters and the dimensions of the final product of the welding specification to be used for the VPPA Welding System operated at MSFC are provided.

Hung, R. J.↗
NASA NTRS1993

Plasma arc welding repair of space flight hardware

A technique to weld repair the main combustion chamber of Space Shuttle Main Engines has been developed. The technique uses the plasma arc welding process and active cooling to seal cracks and pinholes in the hot-gas wall of the main combustion chamber liner. The liner hot-gas wall is made of NARloy-Z, a copper alloy previously thought to be unweldable using conventional arc welding processes. The process must provide extensive heat input to melt the high conductivity NARloy-Z while protecting the delicate structure of the surrounding material. The higher energy density of the plasma arc process provides the necessary heat input while active water cooling protects the surrounding structure. The welding process is precisely controlled using a computerized robotic welding system.

Hoffman, David S.↗
NASA NTRS1978

Technology of welding aluminum alloys-III

Control of porosity in weld beads was major objective in development of aluminum welding program. Porosity, most difficult defect to control, is caused by hydrogen gas unable to escape during solidification. Hard tooling allows hotter bead than free-fall tooling so hydrogen bubbles can boil out instead of forming pores. Welding position, moisture, and cleanliness are other important factors in control of porosity.

Harrison, J. R.↗