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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
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 NTRS1987

Morphology of zirconia particles exposed to D.C. arc plasma jet

Zirconia particles were sprayed into water with an arc plasma gun in order to determine the effect of various gun operating parameters on their morphology. The collected particles were examined by XRD and SEM techniques. A correlation was established between the content of spherical (molten) particles and the operating parameters by visual inspection and regression analysis. It was determined that the composition of the arc gas and the power input were the predominant parameters that affected the melting of zirconia particles.

Zaplatynsky, Isidor↗
DOE OSTI2019

A 6 MW/m 2 High Heat Flux Testing Facility of Irradiated Materials Using Infrared Plasma-Arc Lamps

Assessing the effect of neutron irradiation of plasma-facing materials has been challenging due to both the technical and radiological challenges involved. In an effort to address the radiological challenges, a facility was developed to conduct high heat flux testing (HHFT) of inherently small samples of neutron-irradiated materials. A new line-focus reflector was designed and fabricated at Oak Ridge National Laboratory for a plasma-arc lamp (PAL) to attain a source heat flux of 12 MW/m 2 . The new reflector was fabricated with two ports for monitoring specimen condition during HHFT. At the same operational conditions for PAL, the absorbed heat flux in tungsten was increased from 1.39 MW/m 2 with the uniform irradiance reflector to 5.12 MW/m 2 for the line-focus reflector. This fourfold increase in the heat flux, at the same PAL electrode lifetimes, enabled cost-effective facility operation for a high number of cyclic high heat flux tests. Specifically, the test section is confined to a hemispherical dome, and specimens are bolted directly to a water-cooled copper alloy rod. Temperature measurement in the PAL facility was a main challenge due to a limited line of sight. For the first time in a PAL facility operating at high heat fluxes, the specimen surface temperature was directly measured during HHFT with a pyrometer. Finally, the HHFT data, which were obtained in this upgraded PAL facility, demonstrated the facility readiness for irradiated materials.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1983

Performance of an ablator for Space Shuttle inorbit repair in an arc-plasma airstream

An ablator patch material performed well in an arc plasma environment simulating nominal Earth entry conditions for the Space Shuttle. Ablation tests using vacuum molded cones provided data to optimize the formulation of a two part polymer system for application under space conditions. The blunt cones were made using a Teflon mold and a state of the art caulking gun. Char stability of formulations with various amounts of catalyst and diluent were investigated. The char was found to be unstable in formulations with low amounts of catalyst and high amounts of diluent. The best polymer system determined by these tests was evaluated using a half tile patch in a multiple High Temperature Reusable surface Insulation tile model. It was demonstrated that this ablator could be applied in a space environment using a state of the art caulking gun, would maintain the outer mold line of the thermal protection system during entry, and would keep the bond line temperature at the aluminum tile interface below the design limit.

Stewart, D. A.↗
DOE OSTI2015

Effect of N{sub 2} and Ar gas on DC arc plasma generation and film composition from Ti-Al compound cathodes

DC arc plasma from Ti, Al, and Ti{sub 1−x}Al{sub x} (x = 0.16, 0.25, 0.50, and 0.70) compound cathodes has been characterized with respect to plasma chemistry (charged particles) and charge-state-resolved ion energy for Ar and N{sub 2} pressures in the range 10{sup −6} to 3 × 10{sup −2} Torr. Scanning electron microscopy was used for exploring the correlation between the cathode and film composition, which in turn was correlated with the plasma properties. In an Ar atmosphere, the plasma ion composition showed a reduction of Al of approximately 5 at. % compared to the cathode composition, while deposited films were in accordance with the cathode stoichiometry. Introducing N{sub 2} above ∼5 × 10{sup −3} Torr, lead to a reduced Al content in the plasma as well as in the film, and hence a 1:1 correlation between the cathode and film composition cannot be expected in a reactive environment. This may be explained by an influence of the reactive gas on the arc mode and type of erosion of Ti and Al rich contaminations, as well as on the plasma transport. Throughout the investigated pressure range, a higher deposition rate was obtained from cathodes with higher Al content. The origin of generated gas ions was investigated through the velocity rule, stating that the most likely ion velocities of all cathode elements from a compound cathode are equal. The results suggest that the major part of the gas ions in Ar is generated from electron impact ionization, while gas ions in a N{sub 2} atmosphere primarily originate from a nitrogen contaminated layer on the cathode surface. The presented results provide a contribution to the understanding processes of plasma generation from compound cathodes. It also allows for a more reasonable approach to the selection of composite cathode and experimental conditions for thin film depositions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2018

Mechanism of Desulfurization from Liquid Iron by Hydrogen Plasma Arc Melting

In this study, desulfurization from liquid iron by Ar and (10 to 40 pct)H{sub 2} + Ar plasma arc melting (HPAM) was examined. The experimental results show that the rate of desulfurization increases as hydrogen is added proportionally to plasma gas. The thermodynamic analysis suggests that the interaction of activated atomic hydrogen and dissolved sulfur in liquid iron, [S]+2H=H{sub 2}S, could be taking place. The kinetic analysis confirms that the desulfurization from liquid iron obeys a first-order rate law.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Heat sink effects in variable polarity plasma arc welding

The Space Shuttle External Tank is fabricated by the variable polarity plasma arc (VPPA) welding process. In VPPA welding, a noble gas, usually argon, is directed through an arc to emerge from the torch as a hot plasma jet. This jet is surrounded by a shielding gas, usually helium, to protect the weld from contamination with air. The high velocity, hot plasma jet completely penetrates the workpiece (resembling a line heat source) when operated in the 'keyhole' mode. The metal melts on touching the side of the jet, as the torch travels in the perpendicular direction to the direction of the jet, and melted metal moves around the plasma jet in the keyhole forming a puddle which solidifies behind the jet. Heat sink effects are observed when there are irregularities in the workpiece configuration, especially, if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, i.e., in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of this research is to study the effect of irregularities in workpiece configuration and fixture differences (heat sink effects) on the weld bead geometry with the ultimate objective to compensate for the heat sink effects and achieve a perfect weld. Experiments were performed on different workpiece geometries and compared to approximate models.

Abdelmessih, Amanie N.↗
DOE OSTI2020

Investigation of flow regimes in arc plasma–gas interactions using a two-temperature arc in crossflow model

The perpendicular impingement of a gas stream on an electric arc, a configuration known as the arc in crossflow, is of primary relevance in the study of plasma-gas interactions, as well as in industrial applications such as circuit breakers and wire-arc spraying. The flow dynamics in the arc in crossflow are the result of coupled fluid-thermal-electromagnetic phenomena accompanied by large property gradients, which can produce significant deviations from Local Thermodynamic Equilibrium (LTE) among electrons and gas species. These characteristics can lead to the establishment of distinct flow regimes depending on the relative values of the controlling parameters of the system, such as inflow velocity, arc current, and inter-electrode spacing. A two-temperature non-LTE (NLTE) model is used to investigate the arc dynamics and the establishment of flow regimes in the arc in crossflow. The plasma flow model is implemented within a nonlinear Variational Multiscale (VMS) numerical discretization approach that is less dissipative, and hence better suited to capture unstable behavior, than traditional VMS methods commonly used in computational fluid dynamics simulations. The Reynolds and the Enthalpy dimensionless numbers, characterizing the relative flow strength and arc strength, respectively, are chosen as the controlling parameters of the system. Simulation results reveal the onset of dynamic behavior and the establishment of steady, periodic, quasi-periodic, and chaotic or potentially turbulent, regimes, as identified by distinct spatiotemporal fluctuations. The computational findings reveal the role of increasing the relative arc strength on enhancing flow stability by delaying the growth of fluctuating and unstable flow behavior.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1991

The variable polarity plasma arc welding process: Characteristics and performance

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. The power distribution was analyzed for an argon plasma gas flow constituting the fluid in the VPPA Welding Process. The major heat loss at the torch nozzle is convective heat transfer; in the space between the outlet of the nozzle and the workpiece; radiative heat transfer; and in the keyhole in the workpiece, convective heat transfer. The power absorbed at the workpiece produces the molten puddle that solidifies into the weld bead. Crown and root widths, and crown and root heights of the weld bead are predicted. The basis is provided for an algorithm for automatic control of VPPA welding machine parameters to obtain desired weld bead dimensions.

Hung, R. J.↗
DOE OSTI2016

Note: Triggering behavior of a vacuum arc plasma source

Axial symmetry of discharge is very important for application of vacuum arc plasma. It is discovered that the triggering method is a significant factor that would influence the symmetry of arc discharge at the final stable stage. Using high-speed multiframe photography, the transition processes from cathode-trigger discharge to cathode-anode discharge were observed. It is shown that the performances of the two triggering methods investigated are quite different. Arc discharge triggered by independent electric source can be stabilized at the center of anode grid, but it is difficult to achieve such good symmetry through resistance triggering. It is also found that the triggering process is highly correlated to the behavior of emitted electrons.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2003

New Voltage and Current Thresholds Determined for Sustained Space Plasma Arcing

It has been known for many years, based partly on NASA Glenn Research Center testing, that high-voltage solar arrays arc into the space plasma environment. Solar arrays are composed of solar cells in series with each other (a string), and the strings may be connected in parallel to produce the entire solar array power. Arcs on solar arrays can damage or destroy solar cells, and in the extreme case of sustained arcing, entire solar array strings, in a flash. In the case of sustained arcing (discovered at Glenn and applied to the design and construction of solar arrays on Space Systems/Loral (SS/Loral, Palo Alto, CA) satellites, Deep-Space 1, and Terra), an arc on one solar array string can couple to an adjacent string and continue to be powered by the solar array output until a permanent electrical short is produced. In other words, sustained arcs produced by arcs into the plasma (so-called trigger arcs) may turn into disastrous sustained arcs by involving other array strings.

Dale C. Ferguson↗
DOE OSTI2020

Unipolar arc plasmas on nanostructured tungsten surfaces under perpendicular magnetic field

Abstract Unipolar arcing is an important phenomenon in terms of wall erosion and the subsequent plasma contamination in nuclear fusion devices. In this study, unipolar arc plasmas are experimentally explored under the presence of the external magnetic field perpendicular to a tungsten (W) sample on which a ‘fuzz’ nanostructure surface is formed. It is found that the fuzz layer thickness, d fuzz , plays a dominant role in determining the motion of arc spots, the arc ignition probability, and arc plasma parameters. High-speed imaging reveals that the motion of arc spots becomes more collective, as d fuzz increases. Interestingly, arc spots make a circle while moving outward. With increasing d fuzz , the amount of eroded W atoms increases, as indicated from an observed increase in the total visible emission intensity, while the arc ignition probability is found to drop. The physical mechanisms are discussed, in detail, based on spectroscopic measurements of the electron temperature, obtained from Boltzmann plots of both W I and W II, and the electron density, determined from Stark broadening of W I lines.

Physics↗
NASA NTRS1974

Performance of coated columbium and tantalum alloys in plasma arc reentry simulation tests

The evaluation of coated refractory metals screened in stagnation model plasma arc tests is reported. Columbium alloys FS-85, C-129Y, and Cb-752 coated with Si-20Cr-20Fe (R512E) were tested at 1390 C. Three silicide coatings on Ta-10W were tested at 1470 C. Half-hour cycles and a 6500 N/sqm stagnation pressure were used. The best R512E coated columbium alloy was FS-85 with first local coating breakdowns occurring in 12 to 50 cycles. At coating defects, low metal recession rates (0.005 mm/min) were generally observed on coated columbium alloys while high rates (0.15 mm/min) were observed on coated Ta-10W. Coated columbium suffered large emittance losses (to below 0.7) due to surface refractory metal pentoxide formation.

Levine, S. R.↗
NASA NTRS1989

Variable-Polarity Plasma Arc Welding Of Alloy 2219

Report presents results of study of variable-polarity plasma arc (VPPA) welding of aluminum alloy 2219. Consists of two parts: Examination of effects of microsegregation and transient weld stress on macrosegregation in weld pool and, electrical characterization of straight- and reverse-polarity portions of arc cycle.

Walsh, Daniel W.↗
DOE OSTI2019

Microstructure and Work Hardening Behavior of Micro-plasma Arc Welded AISI 316L Sheet Joint

The aim of this research is to investigate the microstructural changes and work hardening behavior of AISI 316L 0.5-mm-thick sheet due to micro-plasma arc welding. AISI 316L similar sheets were welded in single-pass square butt joint configuration. The microstructure in the fusion zone typically contains a variety of complex δ-ferrite-austenitic structure, which significantly increased hardness value compared to the base material because of rapid solidification of the weld pool. Systematic tensile test was performed to investigate strain rate sensitivity of the welded joint under quasi-static loading conditions. The multistage work hardening behavior was determined by Kocks–Mecking (K–M) model and differential Crussard–Jaoul analysis. In both the cases, stage III work hardening behavior and stage IV work hardening behavior were observed. The stress–strain curves of welded specimen at different strain rates were analyzed in terms of Hollomon, Ludwik and Swift equations to determine work hardening exponent values. The welded joints were ruptured in the transition zone of heat affected and fusion zones. The fractographic observation exhibited variation in dimple and void density over strain rate from 0.0001 to 0.0015 s{sup −1}.

36 MATERIALS SCIENCE↗