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At least 73 records · Page 4

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NASA NTRS2014

Weld Nugget Temperature Control in Thermal Stir Welding

A control system for a thermal stir welding system is provided. The control system includes a sensor and a controller. The sensor is coupled to the welding system's containment plate assembly and generates signals indicative of temperature of a region adjacent and parallel to the welding system's stir rod. The controller is coupled to the sensor and generates at least one control signal using the sensor signals indicative of temperature. The controller is also coupled to the welding system such that at least one of rotational speed of the stir rod, heat supplied by the welding system's induction heater, and feed speed of the welding system's weld material feeder are controlled based on the control signal(s).

Ding, R. Jeffrey↗

NASA NTRS1968

Automatic contour welder incorporates speed control system

Speed control system maintains the welding torch of an automatic welder at a substantially constant speed. The system is particularly useful when welding contoured or unusually shaped surfaces, which cause the distance from the work surface to the weld carriage to vary in a random manner.

Wall, W. A., Jr.↗

NASA NTRS1990

Rolling Spot Welder

Wheeled tool speeds tack-welding operations. Spotwelds foil to parts in preparation for brazing. Includes electrode wheel rolling across foil. Welding current in electrode pulsed as electrode moves along, making series of uniformly-spaced low-current spot welds.

Wagner, Garret E.↗

NASA NTRS1992

Algorithm For Simplified Robotic Tracking Of Weld Seams

Algorithm computes small cross-seam corrections to programmed path of welding robot. Intended for use with add-on vision system loosely coupled to robot, transmitting small amount of information about weld seam ahead of torch. Position of welding torch in reference frame of moving window estimated on basis of data on weld seam and speed of torch. Does not need data on position of torch, and does not transform data on seam to another reference frame.

Gutow, David A.↗

NASA NTRSDate not supplied

Development and Application of Weld Track Thermal Analysis for the Exploration Extravehicular Mobility Unit

NASA is studying the next generation of space suit for safe operations in space, from the International Space Station to the lunar surface as part of the Exploration Extravehicular Mobility Unit project. The backplate structure of the portable life support system (PLSS) serves as the attachment point for assembly of the PLSS and contains embedded cooling channels. The thermal loop plumbing assembly and backplate are combined into a single component such that the fluid lines run through the midplane of the backplate. The manufacturing of the Ti-6Al-4V backplate consists of machining channels into a plate, welding cover plates on each channel using an electron beam, and additional machining for excess material removal and final detail. Careful control of the electron beam weld process is necessary to completely seal cover plates, produce consistent weld tracks, and produce channels with uniform cross sections free of debris and defects. The backplate contains multiple weld channels with unique geometries. The weld process parameters include choosing the beam current and focus, accelerating voltage, travel speed, pause times between weld tracks, and sequence of weld tracks. A transient finite element thermal analysis was developed to provide support for choosing and controlling the weld process parameters to maintain a consistent melt pool along each of the weld tracks. A moving distributed heat source is modeled to represent the heat input generated by the electron beam. The heat source model is a critical input to the analysis for accurate temperature predictions during the weld process. A modified conical heat source was developed to account for the change in working distance between the backplate and cover plates. The geometry of the material being welded must be accounted for by the heat source model to define the correct energy input. The weld process control is designed according to the predicted thermal history and melt pool dimensions for each of the weld channels. The analysis model, modified heat source, temperature and melt pool predictions, application of the thermal data to the weld parameters, and comparison with micrograph cross-sections from weld trials will be discussed in this presentation.

Electron Beam Welding↗

NASA NTRS1993

Method for defect free keyhole plasma arc welding

A plasma arc welding process for welding metal of increased thickness with one pass includes operating the plasma arc welding apparatus at a selected plasma gas flow rate, travel speed and arc current, to form a weld having a penetration ratio to weld height to weld width, and maintaining the penetration ratio at less than 0.74. Parameters for the plasma gas flow rate, travel speed and arc current are adjusted to a steady state condition during a start up period and maintained during the steady state condition to complete a weld. During a terminal stopping period, the travel speed is stopped and instantaneously replaced by filler wire which adds material to fill the keyhole that had been formed by the welding process. Parameters are subsequently adjusted during the stopping period to terminate the weld in a sound manner.

Harwig, Dennis D.↗

NASA NTRS2010

Prolegomena to the Study of Friction Stir Welding

The literature contains many approaches toward modeling of the friction stir welding (FSW) process with varying treatments of the weld metal properties. It is worthwhile to consider certain fundamental features of the process before attempting to interpret FSW phenomena: Because of the unique character of metal deformation (as opposed to, say, viscous deformation) a velocity "discontinuity" or shear surface occurs in FSW and determines much of the character of the welding mechanism. A shear surface may not always produce a sound bond. Balancing mechanical power input against conduction and convection heat losses yields a relation, a "temperature index", between spindle speed and travel speed to maintain constant weld temperature. But many process features are only weakly dependent upon temperature. Thus, unlike modeling of metal forming processes, it may be that modeling the FSW process independently of the material conditions has some merit.

Nunes, Arthur C., Jr.↗

DOE OSTI2021

Dissimilar joining of ZEK100 and AA6022 for automotive application

Mg and Al joining is problematic due to different high temperature flow characteristics that often results in weld defects and brittle intermetallic compounds (IMC). We present process development on lap joining of 1.27 mm 6022 (top sheet) and 1.5mm ZEK100 (bottom sheet) for an automotive door application. We conducted process development in linear welding using power control mode (modulating torque and spindle speed) with multiple tool designs, and welding parameters. Process variables were correlated to joint micro-structure and mechanical properties. A 2D computational model was created to understand the failure mechanism and contribution of mechanical interlocking towards joint strength. For a thin (< 2 mm) automotive sheet with softer material as a bottom sheet, adequate control of process variables is critical to maintain weld stability and avoid excessive IMC layer at the interface. A combination of mechanical anchoring and metallurgical reaction is likely responsible for bonding.

Das, Hrishikesh↗

DOE OSTI2026

Process-driven roadmap for depositing super duplex stainless steel via wire Arc additive manufacturing

Here, this study systematically investigates the effects of shielding gas, bead spacing, weld mode, and travel speed on the phase balance, porosity, and hardness of wire arc additively manufactured (WAAM) super duplex stainless steel (ER2594). Robotic WAAM was employed to fabricate multilayer walls under systematically varied process conditions, followed by phase transformation simulations, X-ray computed tomography (XCT), electron backscatter diffraction (EBSD), and microhardness evaluation. Thermodynamic simulations predicted rapid cooling of AM process can suppress the potential formation of deleterious precipitates which was later validated via cross-sectional microstructure analyses of printed samples. XCT revealed porosity levels below 0.2% for all deposits, with reduced travel speed significantly lowering defect volume. Microstructural analyses revealed the evolution of various austenite precipitates, including grain boundary austenite (GBA), Widmanstätten austenite (WA), and intergranular austenite (IGA), sequentially upon cooling of the ferrite phase. Among all process parameters, weld transfer mode exhibited the strongest influence on phase balance; pulsed mode promoted higher ferrite retention (~ 36%) compared to RapidX mode. No consistent relationship between stabilized phase fraction and captured microhardness was observed. This work provides critical insights for optimizing WAAM parameters to control phase balance and mechanical performance, which is essential for producing high-integrity super duplex stainless-steel components for nuclear and marine applications.

Grain orientation↗

DOE OSTI2022

High Strength Steel-Aluminum Components by Vaporizing Foil Actuator Welding

This project aimed to address the challenge of effectively welding dissimilar materials—high-strength steel and high-strength aluminum for creating lightweight, multi-material automotive components. For automotive companies, reducing weight of a vehicle is critical task regulated by the government to solve the issue of greenhouse gas emissions. Production of lightweight cars and trucks can be achieved by substitution of current all-steel structures with multi-material lightweight structures that include high strength-to-weight-ration materials such as high-strength steels, aluminum alloys, magnesium alloys, titanium alloys, coupled with lightweight designs. This requires dissimilar metal welding, which is challenging for state of the art joining processes such as resistance spot welding. The cycle of melting-cooling-freezing during traditional welding that can easily ruin the designed outstanding properties of the advanced base metals, such as aluminum alloys, making the welded area much weaker than the base metals. To weld two different metals with great difference in melting points, such as aluminum and steel, it’s even more difficult or impossible because of the formation of brittle intermetallic compounds at the welded interface. In this project, a novel welding method, developed at OSU, was selected for validation and development. This novel technology enables welding by impact without melting and proves to be robust to join various dissimilar lightweight metals. Termed as vaporizing foil actuator welding or VFAW, the technology uses a thin aluminum foil that is rapidly vaporized by a high current pulse to produce an explosive-like pressure pulse to drive one metallic piece into another at the high speed required for impact welding. This project entailed development of the early-stage welding technology in terms of (a) the consumables, the welding apparatus and the power sources, (b) coupon scale screening of many material combinations including corrosion studies, (c) computational modeling and design of the welded interface as well as of the multi-material prototype component, and (d) mechanical testing for strength and durability at coupon scale and to a certain extent the prototype scale. The all-steel engine cradle of 2016 Chevrolet Cruze was chosen as the baseline prototype component. The target set for the project was to demonstrate a 20% weight reduction at a cost premium of less than $\$ $5/lb saved without compromising on baseline mechanical properties. At project completion, a 12% lighter prototype component was demonstrated with an estimated cost premium of $\$ $9.8/lb saved. Besides prototype level demonstration of the technology, this project also enabled elevation of the technology’s readiness level to where a hydraulically actuated welding head was developed and made ready for deployment at a research and development facility for Tier 1 automotive supplier.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Ultrasonic measurement of stress in railroad wheels and in long lengths of welded rail

The failure of high speed emergency braking is discussed for railroad wheels and track. It is shown that high compressive residual stresses exist in the rims of new wheels which generate excessive heat, reducing the stress levels. Thermal stresses that build up in continuous lengths of welded track are reported and nondestructive methods of measuring stresses in thick steel are presented for identification, replacement, or adjustment before hazardous failures occur.

Clotfelter, W. N.↗

NASA NTRS2003

Thermo-Mechanical Processing in Friction Stir Welds

Friction stir welding is a solid-phase joining, or welding process that was invented in 1991 at The Welding Institute (TWI). The process is potentially capable of joining a wide variety of aluminum alloys that are traditionally difficult to fusion weld. The friction stir welding (FSW) process produces welds by moving a non-consumable rotating pin tool along a seam between work pieces that are firmly clamped to an anvil. At the start of the process, the rotating pin is plunged into the material to a pre-determined load. The required heat is produced by a combination of frictional and deformation heating. The shape of the tool shoulder and supporting anvil promotes a high hydrostatic pressure along the joint line as the tool shears and literally stirs the metal together. To produce a defect free weld, process variables (RPM, transverse speed, and downward force) and tool pin design must be chosen carefully. An accurate model of the material flow during the process is necessary to guide process variable selection. At MSFC a plastic slip line model of the process has been synthesized based on macroscopic images of the resulting weld material. Although this model appears to have captured the main features of the process, material specific interactions are not understood. The objective of the present research was to develop a basic understanding of the evolution of the microstructure to be able to relate it to the deformation process variables of strain, strain rate, and temperature.

Schneider, Judy↗

NASA NTRS1991

Welding space vacuum technology

The objective was to assist the EH 42 Division in putting together a vacuum system that could attain the desired pressure and be large enough to accommodate the gas-metal arc (GMA) welding fixture apparatus. A major accomplishment was the design and fabrication of the controller/annunciator for the 4' by 8' system. It contains many safety features such as thermocouple set point relays that will only allow inlet and exit gas and vacuum valves to be operated at pre-selected system pressures, and a fail safe mode for power interruptions and operator mistakes. It is felt that significant progress was made in this research effort to weld in a vacuum environment. With continued efforts to increase the pump speeds for vacuum chambers and further studies on weld fixtures and gas inlet pressures, the NASA program will be successful.

Johnson, R. Barry↗

NASA NTRS1991

Fast, Nonspattering Inert-Gas Welding

Proposed welding technique combines best features of metal (other than tungsten)/inert-gas welding, plasma arc welding, and tungsten/inert-gas welding. Advantages include: wire fed to weld joint preheated, therefore fed at high speed without spattering; high-frequency energy does not have to be supplied to workpiece to initiate welding; size of arc gap not critical, power-supply control circuit adjusts voltage across gap to compensate for changes; only low gas-flow rate needed; welding electrode replaced easily as prefabricated assembly; external wire-feeding manipulator not needed; and welding process relatively forgiving of operator error.

Gilbert, Jeffrey L.↗

NASA NTRS1938

The Effect of Surface Irregularities on Wing Drag. I. Rivets and Spot Welds: Rivets and Spot Welds - 1

Tests have been conducted in the NACA 8-foot high-speed wind tunnel to determine the effect of exposed rivet heads and spot welds on wing drag. Most of the tests were made with an airfoil of 5-foot chord. The air speed was varied from 80 to 500 miles per hour and the lift coefficient from 0 to 0.30. The increases in the drag of the 5-foot airfoil varied from 6%, due to countersunk rivets, to 27%, due to 3/32-inch brazier-head rivets, with the rivets in a representative arrangement. The drag increases caused by protruding rivet heads were roughly proportional to the height of the heads. With the front row of rivets well forward, changes in spanwise pitch had negligible effects on drag unless the pitch was more than 2.5% of the chord. Data are presented for evaluating the drag reduction attained by removing rivets from the forward part of the wing surface; for example, it is shown that over 70% of the rivet drag is caused by the rivets on the forward 30% of the airfoil in a typical case.

Hood, Manley J.↗

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 NTRS2001

New Tool Creates a Big Stir

A new self-adjusting, retractable pin tool for friction stir welding is now used in the manufacturing of components for NASA Space Shuttles. Friction stir welding is a process that makes straight-line welds without bringing the parent material to a liquid state. This is accomplished through high-speed rotation, which generates frictional heat between the welding tool and the piece being welded. This heat causes the material to soften to the point of plasticity without allowing it to melt. The plasticized material is then transferred from the front edge of the welding tool to the trail edge, where it joins the pieces being welded. However, a major flaw of this method is its reliance on a single-piece pin tool. The weld is left unfinished and a hole remains where the pin was inserted. The hole must be covered with a rivet in order to preserve the integrity of the weld. The NASA-developed pin tool, however, eliminates the need for this finishing step, as its retraction allows continuous rewelding at lesser depths, until the hole is completely closed. With this NASA technology, welding of higher strength alloys, as well as non-planer and variable thickness structures can be achieved.

Source record↗

NASA NTRS2004

Heat Control via Torque Control in Friction Stir Welding

In a proposed advance in friction stir welding, the torque exerted on the workpiece by the friction stir pin would be measured and controlled in an effort to measure and control the total heat input to the workpiece. The total heat input to the workpiece is an important parameter of any welding process (fusion or friction stir welding). In fusion welding, measurement and control of heat input is a difficult problem. However, in friction stir welding, the basic principle of operation affords the potential of a straightforward solution: Neglecting thermal losses through the pin and the spindle that supports it, the rate of heat input to the workpiece is the product of the torque and the speed of rotation of the friction stir weld pin and, hence, of the spindle. Therefore, if one acquires and suitably processes data on torque and rotation and controls the torque, the rotation, or both, one should be able to control the heat input into the workpiece. In conventional practice in friction stir welding, one uses feedback control of the spindle motor to maintain a constant speed of rotation. According to the proposal, one would not maintain a constant speed of rotation: Instead, one would use feedback control to maintain a constant torque and would measure the speed of rotation while allowing it to vary. The torque exerted on the workpiece would be estimated as the product of (1) the torque-multiplication ratio of the spindle belt and/or gear drive, (2) the force measured by a load cell mechanically coupled to the spindle motor, and (3) the moment arm of the load cell. Hence, the output of the load cell would be used as a feedback signal for controlling the torque (see figure).

Venable, Richard↗