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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Ignition characterization of the GOX/ethanol propellant combination

This paper describes the results of a study to define the ignition characteristics and thruster pulse mode capabilities of the GOX/ethanol propellant combination. Ignition limits were defined in terms of mixture ratio and cold flow pressure using a spark initiated torch igniter. Igniter tests were run over a wide range of cold flow pressure, propellant temperature and mixture ratio. The product of cold flow pressure and igniter chamber diameter was used to correlate mixture ratio regimes of ignition and nonignition. Engine ignition reliability and pulse mode capability were demonstrated using a 620 lbF thruster with an integrated torch igniter. The nominal chamber pressure and mixture ratio were 150 psia and 1.8, respectively, thruster tests were run over a wide range of chamber pressures and mixture ratios. The feasibility of thruster pulse mode operation with the non-hypergolic GOX/ethanol propellant combination was demonstrated.

Lawver, B. R.↗
NASA NTRS1984

Variable polarity plasma arc welding on the Space Shuttle external tank

Variable polarity plasma arc (VPPA) techniques used at NASA's Marshall Space Flight Center for the fabrication of the Space Shuttle External Tank are presentedd. The high plasma arc jet velocities of 300-2000 m/s are produced by heating the plasma gas as it passes through a constraining orifice, with the plasma arc torch becoming a miniature jet engine. As compared to the GTA jet, the VPPA has the following advantages: (1) less sensitive to contamination, (2) a more symmetrical fusion zone, and (3) greater joint penetration. The VPPA welding system is computerized, operating with a microprocessor, to set welding variables in accordance with set points inputs, including the manipulator and wire feeder, as well as torch control and power supply. Some other VPPA welding technique advantages are: reduction in weld repair costs by elimination of porosity; reduction of joint preparation costs through elimination of the need to scrape or file faying surfaces; reduction in depeaking costs; eventual reduction of the 100 percent-X-ray inspection requirements. The paper includes a series of schematic and block diagrams.

Nunes, A. C., Jr.↗
NASA NTRS1988

Tool Removes Arc-Light Reflectors

New tool makes installation, adjustment, and removal of self-clamping arc-light reflectors on welding torches easy and simple. Consists of two arms reaching around from back of torch. Lip on each arm hooks into slot of arc-light reflector clamp. When handles squeezed together, slot spreads enabling easy installation, adjustment, or removal of reflector without disassembly of welding apparatus.

Gordon, Stephen S.↗
NASA NTRS1988

Flexible Protective Shield For Newly Welded Joints

Simple device promotes defect-free welds in oxidation-prone metals. Welding torch pulls trailing shield behind to provide protective shield of argon gas over hot weld bead. Guide at front of torch holder feeds welding wire to joint. Shield bent or straightened to fit closely against weld joint.

Dyer, Gerald E.↗
NASA NTRS1988

A Generalized Method for Automatic Downhand and Wirefeed Control of a Welding Robot and Positioner

A generalized method for controlling a six degree-of-freedom (DOF) robot and a two DOF positioner used for arc welding operations is described. The welding path is defined in the part reference frame, and robot/positioner joint angles of the equivalent eight DOF serial linkage are determined via an iterative solution. Three algorithms are presented: the first solution controls motion of the eight DOF mechanism such that proper torch motion is achieved while minimizing the sum-of-squares of joint displacements; the second algorithm adds two constraint equations to achieve torch control while maintaining part orientation so that welding occurs in the downhand position; and the third algorithm adds the ability to control the proper orientation of a wire feed mechanism used in gas tungsten arc (GTA) welding operations. A verification of these algorithms is given using ROBOSIM, a NASA developed computer graphic simulation software package design for robot systems development.

Fernandez, Ken↗
NASA NTRS1987

Better welds for launch vehicles

The use and benefits of automated variable polarity plasma arc (VPPA) welding of Al joints are described. The entire welding system, including welding head manipulator, weld-wire feed, torch, and power supply are computer controlled. The importance of proper torch dynamics and the control of argon gas flow through the plasma orifice are discussed. The use of arc-voltage control, the improvements in system monitoring, and the reduction or elimination of electromagnetic interferences are examined. VPPA welding is applicable to joining Space Shuttle components, and an example of its use on an External Tank of the Shuttle is presented.

Schwinghamer, Robert J.↗
NASA NTRS1989

Three-Dimensional Coaxial Weld Monitoring

Optical system for coaxial-viewing welding torch enables perception or measurement of depth. Light from welding area passes through beam splitter into two optical trains forming two images, each viewed along line making small angle with axis of torch. Two lines of sight intersect at weld pool. Parallax between two views provides sensation of depth over entire field view.

Gordon, Stephen S.↗
NASA NTRS1989

Arc-Light Reflector For Television Weld Monitoring

Conical, stainless-steel mirror attached to end of welding torch improves distribution of light on work-piece as welding monitored through torch by television. Television monitoring protects operators from intense arc light and facilitates automated welding. Simple, small, and easy to install and remove, mirror relatively nonintrusive.

Gordon, Stephen S.↗
NASA NTRS1989

Aligning Plasma-Arc Welding Oscillations

Tool aids in alignment of oscillator probe on variable-polarity plasma-arc welding torch. Probe magnetically pulls arc from side to side as it moves along joint. Tensile strength of joint depends on alignment of weld bead and on alignment of probe. Operator installs new tool on front of torch body, levels it with built-in bubble glass, inserts probe in slot on tool, and locks probe in place. Procedure faster and easier and resulting alignment more accurate and repeatable.

Norris, Jeff↗
NASA NTRS1990

Arc Reflector For Welding Ducts

Arc-light reflector for through-the-torch welding vision system designed expressly for use in welding ducts of small diameter. Cylindrical reflector positioned to reflect light diffusely from welding arc onto nearby surface of workpiece for most advantageous viewing along axis of welding torch.

Gilbert, Jeffrey L.↗
NASA NTRS1990

Electrode carrying wire for GTAW welding

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.

Morgan, Gene E.↗
NASA NTRS1991

Self-Aligning Sensor-Mounting Fixture

Optical welding sensors replaced without realignment. Mounting fixture for optical weld-penetration sensor enables accurate and repeatable alignment. Simple and easy to use. Assembled on welding torch, it holds sensor securely and keeps it pointed toward weld pool. Designed for use on gas/tungsten arc-welding torch, fixture replaces multipiece bracket.

Gilbert, Jeffrey L.↗
NASA NTRS1992

Orbital Welding Head Held By Robot

Orbital welding head positioned by robot controls motion and voltage of arc-welding torch mounted in head. New head encircles part at torch end, and held and manipulated by robot arm at opposite end. Entire welding operation automated. Useful for operations in hazardous environments.

Gangl, Kenneth J.↗
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.↗
NASA NTRS1993

Robotic Variable Polarity Plasma Arc (VPPA) Welding

The need for automated plasma welding was identified in the early stages of the Space Station Freedom Program (SSFP) because it requires approximately 1.3 miles of welding for assembly. As a result of the Variable Polarity Plasma Arc Welding (VPPAW) process's ability to make virtually defect-free welds in aluminum, it was chosen to fulfill the welding needs. Space Station Freedom will be constructed of 2219 aluminum utilizing the computer controlled VPPAW process. The 'Node Radial Docking Port', with it's saddle shaped weld path, has a constantly changing surface angle over 360 deg of the 282 inch weld. The automated robotic VPPAW process requires eight-axes of motion (six-axes of robot and two-axes of positioner movement). The robot control system is programmed to maintain Torch Center Point (TCP) orientation perpendicular to the part while the part positioner is tilted and rotated to maintain the vertical up orientation as required by the VPPAW process. The combined speed of the robot and the positioner are integrated to maintain a constant speed between the part and the torch. A laser-based vision sensor system has also been integrated to track the seam and map the surface of the profile during welding.

Jaffery, Waris S.↗
NASA NTRS1953

Altitude Starting Characteristics of an Afterburner with Autoignition and Hot-streak Ignition

An investigation was conducted in an altitude test chamber at the NACA Lewis Laboratory to determine the altitude starting characteristics of an afterburner with autoignition and with hot-streak ignition. Transient afterburner ignition data were obtained over a range of altitudes from 30,000 to 50,000 feet at a flight Mach number of 0.60. Afterburner ignition with a torch igniter located axially at approximately the midpoint of the combustion chamber was possible over the entire range, but ignition ignition with a torch igniter located in the transition section 1 5/8 inches upstream of the turbine stators proved unsatisfactory at an altitude of 50,000 feet due to the inability to obtain flame through the turbine. Increasing the afterburner-inlet total pressure at a constant afterburner fuel-air ratio decreased the afterburner ignition time. Hot-streak ignition was possible within 2 seconds after the time required to obtain the preset, normal afterburner fuel pressure, whereas autoignition required 4 to 7 seconds for the range of altitudes investigated. Following the ignition there was a period of oscillatory operation existing in the engine-afterburner before steady-state operation was attained. The time required for steady-state stable operation decreased as afterburner inlet total pressure increased. The duration of oscillations also decreased with hot-streak ignition because the fuel-air mixture was ignited before a large volume of combustible mixture was accumulated in the afterburner.

Engines, Control - Turbojet↗
NASA NTRS1994

Imaging The Leading Edge Of A Weld

Proposed optical system integrated into plasma arc welding torch provides image of leading edge of weld pool and welding-arc-initiation point. Welding torch aligned better with joint. System includes coherent bundle of optical fibers and transparent cup.

Mcgee, William F.↗
NASA NTRS1994

Plasma arc welding weld imaging

A welding torch for plasma arc welding apparatus has a transparent shield cup disposed about the constricting nozzle, the cup including a small outwardly extending polished lip. A guide tube extends externally of the torch and has a free end adjacent to the lip. First and second optical fiber bundle assemblies are supported within the guide tube. Light from a strobe light is transmitted along one of the assemblies to the free end and through the lip onto the weld site. A lens is positioned in the guide tube adjacent to the second assembly and focuses images of the weld site onto the end of the fiber bundle of the second assembly and these images are transmitted along the second assembly to a video camera so that the weld site may be viewed continuously for monitoring the welding process.

Rybicki, Daniel J.↗