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Lighweight resistance-welding, hand-held gun supplies alternating or direct current over range of 600 to 4,000 A and applies forces from 40 to 60 lb during welding. Used to weld metal sheets in multilayered stacks.
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.
Less inspection time and effort required. New system not only saves considerable inspection time but also enables welding technician to make corrections during welding process to bring nonconforming weld back within specifications.
Gold-plated stainless-steel sideplates, part of a JPL Galileo spacecraft electronic-relay assembly, exhibited blistering after resistance spot welding. Unacceptable relays had heavy nonuniform gold electrodeposited layers with thicknesses 4.5-11.5 microns. SEM and metallographic investigations indicated much higher heat input generated during the resistance spot welding in unacceptable relays. The attributes of acceptable welded relays are contrasted with unacceptable relays; the possible mechanism of laminar formation of polymeric material in the gold plating is discussed; and some recommendations are provided to prevent similar problems.
Proposed tool measures alignments of plates before butt-welded. Provides nearly instantaneous check on alignment, thereby facilitating repetitive measurements along length of weld joint. Reduces risk of contamination of weld from dirty measuring tools. Middle photodetector indicates acceptable alignment when position of transmitter fiber preciously matches that of center receiver fiber. If plates offset, other photodetectors signal misalignment.
Computer tomography system used to inspect welds for root penetration. Source illuminates rotating welded part with fan-shaped beam of x rays or gamma rays. Detectors in circular array on opposite side of part intercept beam and convert it into electrical signals. Computer processes signals into image of cross section of weld. Image displayed on video monitor. System offers only nondestructive way to check penetration from outside when inner surfaces inaccessible.
Proposed remote vision system provides simultaneous viewing of front and back of workpiece while being welded. Enables human or automatic controller to monitor both weld pool on front and weld penetration on back. Nitrogen laser generates ultraviolet light, distributed to both sides of workpiece through two optical fiber cables. Image-intensifier tubes convert reflected ultraviolet light to visible light. Video cameras equipped with high-resolution charge-coupled devices convert visible outputs of image intensifiers into images for viewing on video monitors.
The In-Space Technology Experiments Program (INSTEP) provides an opportunity to explore the many critical questions which can only be answered by experimentation in space. The objective of the Extravehicular Activity Welding Experiment definition project was to define the requirements for a spaceflight experiment to evaluate the feasibility of performing manual welding tasks during EVA. Consideration was given to experiment design, work station design, welding hardware design, payload integration requirements, and human factors (including safety). The results of this effort are presented. Included are the specific objectives of the flight test, details of the tasks which will generate the required data, and a description of the equipment which will be needed to support the tasks. Work station requirements are addressed as are human factors, STS integration procedures and, most importantly, safety considerations. A preliminary estimate of the cost and the schedule for completion of the experiment through flight and postflight analysis are given.
Parallel gap resistance welding was used to attach lead wires to sputtered thin film sensors. Ranges of optimum welding parameters to produce an acceptable weld were determined. The thin film sensors were Pt13Rh/Pt thermocouples; they were mounted on substrates of MCrAlY-coated superalloys, aluminum oxide, silicon carbide and silicon nitride. The entire sensor system is designed to be used on aircraft engine parts. These sensor systems, including the thin-film-to-lead-wire connectors, were tested to 1000 C.
A welding torch for gas tungsten arc welding apparatus has a hollow tungsten electrode including a ceramic liner and forms the filler metal wire guide. The wire is fed through the tungsten electrode thereby reducing the size of the torch to eliminate clearance problems which exist with external wire guides. Since the wire is preheated from the tungsten more wire may be fed into the weld puddle, and the wire will not oxidize because it is always within the shielding gas.
This paper describes an application of computed tomography (CT) for an evaluation of a series of welding-end hydraulic accumulators in use at Kennedy Space Center, which were suspected of possibly containing fatigue cracks in their welds, the failure which could result in a high-velocity or high-volume leakage of hydraulic fluid. The accumulator welds were evaluated in terms of incomplete penetration, porosity, and incomplete fusion. Out of 43 accumulators examined, six were given the ranking of 'good', i.e., having no incomplete penetration, and only slight porosity and incomplete fusion. These were selected for use in most critical locations of the hydraulic system used to load the Magellan spacecraft into the payload bay of the Space Shuttle Discovery, with the resulting successful loading and subsequent launching of the Magellan spacecraft.
Simple modification yields welds of better quality. Reed valve halves fluctuations in pressure in back-purge chamber attached to workpiece undergoing keyhole plasma arc welding. Identical to one used in fuel system of two-cycle gasoline engine. Backbead smoother, and weld penetrates more uniformly.
Third-generation profilometer for inspection of butt welds includes hand-held probe unit operating in conjunction with computer. Unit positioned across weld, in contact with workpiece, to obtain profile. Increases precision by reducing subjective inputs and concomitant variations in outputs among different operators. Computerization retains capabilities of first- and second-generation profilometers to measure peak angles and mismatches of butt welds and extends measurement capabilities into field of image analysis. Output data more readily processable into forms used by same or another computer.
Computer simulations, robotic inspections, and visual inspections performed to detect discrepancies. Method for verification of tooling for robotic welding involves combination of computer simulations and visual inspections. Verification process ensures accuracy of mathematical model representing tooling in off-line programming system that numerically simulates operation of robotic welding system. Process helps prevent damaging collisions between welding equipment and workpiece, ensures tooling positioned and oriented properly with respect to workpiece, and/or determines whether tooling to be modified or adjusted to achieve foregoing objectives.
Report describes theoretical and experimental study of absorption of heat by metal blocks in contact with metal plate while plate subjected to variable-polarity plasma-arc (VPPA) welding. Purpose of study to contribute to development of comprehensive mathematical model of temperature in weld region. Also relevant to welding of thin sheets of metal to thick blocks of metal, heat treatment of metals, and hotspots in engines.
Adjustable-angle holder enables use of standard straight electrode with custom-fabricated bent gas cup for welding in difficult-to-reach places. Electrode replaced easily, without removing cup, with aid of tool loosening miniature collet nut on holder. Consumes fewer electrodes for given amount of welding. Angle of holder continuously adjustable to fit angle of gas cup or geometry of part welded. Holder made double-jointed to accommodate gas cup having compound angles.
Coaxial-view torch for gas/tungsten arc welding has only two-thirds length and width of its predecessor. Shape and size similar to that of commercial arc-welding torch (Linde HW-27 or equivalent), even though it contains lens system. Collet that holds electrode has unique design allowing greater passage of light. Used in small spaces previously inaccessible, also introduced into production welding operations with minimum of disturbance.
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.