High Power Diode Laser-Treated HP-HVOF and Twin Wire Arc-Sprayed Coatings for Fossil Fuel Power Plants

NASA Astrophysics Data System (ADS)

Mann, B. S.

2013-08-01

This article deals with high power diode laser (HPDL) surface modification of twin wire arc-sprayed (TWAS) and high pressure high velocity oxy-fuel (HP-HVOF) coatings to combat solid particle erosion occurring in fossil fuel power plants. To overcome solid particle impact wear above 673 K, Cr3C2-NiCr-, Cr3C2-CoNiCrAlY-, and WC-CrC-Ni-based HVOF coatings are used. WC-CoCr-based HVOF coatings are generally used below 673 K. Twin wire arc (TWA) spraying of Tafa 140 MXC and SHS 7170 cored wires is used for a wide range of applications for a temperature up to 1073 K. Laser surface modification of high chromium stainless steels for steam valve components and LPST blades is carried out regularly. TWA spraying using SHS 7170 cored wire, HP-HVOF coating using WC-CoCr powder, Ti6Al4V alloy, and high chromium stainless steels (X20Cr13, AISI 410, X10CrNiMoV1222, 13Cr4Ni, 17Cr4Ni) were selected in the present study. Using robotically controlled parameters, HPDL surface treatments of TWAS-coated high strength X10CrNiMoV1222 stainless steel and HP-HVOF-coated AISI 410 stainless steel samples were carried out and these were compared with HPDL-treated high chromium stainless steels and titanium alloy for high energy particle impact wear (HEPIW) resistance. The HPDL surface treatment of the coatings has improved the HEPIW resistance manifold. The improvement in HPDL-treated stainless steels and titanium alloys is marginal and it is not comparable with that of HPDL-treated coatings. These coatings were also compared with "as-sprayed" coatings for fracture toughness, microhardness, microstructure, and phase analyses. The HEPIW resistance has a strong relationship with the product of fracture toughness and microhardness of the HPDL-treated HP-HVOF and TWAS SHS 7170 coatings. This development opens up a possibility of using HPDL surface treatments in specialized areas where the problem of HEPIW is very severe. The HEPIW resistance of HPDL-treated high chromium stainless steels and titanium alloys, HPDL-treated TWAS SHS 7170 and HP-HVOF coatings, and their micrographs and X-ray diffraction analysis is reported in this article.

High-Performance Molybdenum Coating by Wire–HVOF Thermal Spray Process

NASA Astrophysics Data System (ADS)

Tailor, Satish; Modi, Ankur; Modi, S. C.

2018-04-01

Coating deposition on many industrial components with good microstructural, mechanical properties, and better wear resistance is always a challenge for the thermal spray community. A number of thermal spray methods are used to develop such promising coatings for many industrial applications, viz. arc spray, flame spray, plasma, and HVOF. All these processes have their own limitations to achieve porous free, very dense, high-performance wear-resistant coatings. In this work, an attempt has been made to overcome this limitation. Molybdenum coatings were deposited on low-carbon steel substrates using wire-high-velocity oxy-fuel (W-HVOF; WH) thermal spray system (trade name HIJET 9610®). For a comparison, Mo coatings were also fabricated by arc spray, flame spray, plasma spray, and powder-HVOF processes. As-sprayed coatings were analyzed using x-ray diffraction, scanning electron microscopy for phase, and microstructural analysis, respectively. Coating microhardness, surface roughness, and porosity were also measured. Adhesion strength and wear tests were conducted to determine the mechanical and wear properties of the as-sprayed coatings. Results show that the coatings deposited by W-HVOF have better performance in terms of microstructural, mechanical, and wear resistance properties, in comparison with available thermal spray process (flame spray and plasma spray).

Heat treated twin wire arc spray AISI 420 coatings under dry and wet abrasive wear

NASA Astrophysics Data System (ADS)

Rodriguez, E.; González, M. A.; Monjardín, H. R.; Jimenez, O.; Flores, M.; Ibarra, J.

2017-11-01

The influence of applying two different heat treatments such as: deep cryogenic and tempering on dry/wet abrasive wear resistance of twin wire arc spray martensitic AISI 420 coatings was evaluated by using a modified rubber wheel type test apparatus. A load dependency was observed on the abrasive wear rate behavior of both; dry and wet tests. Three body (rolling) and two body (sliding) wear mechanisms were identified in dry conditions, prevailing rolling at lower and higher loads. However, at higher loads, more presence of grooving and pits formation was observed. Coatings tempered at 205 °C/1 h displayed better wear resistance than cryogenic treated ones. A change in wear mechanism between dry and wet conditions was observed; two body wear mechanism predominated respect to three body. In both; dry and wet conditions the microstructure (several inter-splat oxides) as well as strain and residual stress promotes brittle material removal which was more evident in cryogenic and as-sprayed samples during dry test and at higher loads in wet conditions.

Effect of Porosity Content of Arc-Sprayed Alloy 625 Skins on the Flexural Behavior of Nickel Foam Core Sandwich Structures

NASA Astrophysics Data System (ADS)

Salavati, S.; Pershin, L.; Coyle, T. W.; Mostaghimi, J.

2015-01-01

Metallic foam core sandwich structures have been of particular interest for engineering applications in recent decades because of their unique mechanical and physical properties. Thermal spraying techniques have been recently introduced as a novel low-cost method for production of these structures with complex shapes. One of the potential applications of the metallic foam core sandwich structures prepared by thermal spray techniques is as heat shield devices. Open porosity in the microstructure of the coating may allow the cooling efficiency of the heat shield to be improved through the film cooling phenomenon. A modified twin wire-arc spraying process was employed to deposit high temperature resistant alloy 625 coatings with a high percentage of the open porosity. The effect of skin porosity on the mechanical properties (flexural rigidity) of the sandwich structures was studied using a four-point bending test. It was concluded from the four-point bending test results that increase in the porosity content of the coatings leads to decrease in the flexural rigidity of the sandwich panels. The ductility of the porous and conventional arc-sprayed alloy 625 coatings was improved after heat treatment at 1100 °C for 3 h.

Mapping the droplet transfer modes for an ER100S-1 GMAW electrode

DOE Office of Scientific and Technical Information (OSTI.GOV)

Heald, P.R.; Madigan, R.B.; Siewert, T.A.

1994-02-01

Welds were made with a 1.2-mm-diameter AWS ER100S-1 electrode using Ar-2% O[sub 2] shielding gas to map the effects of contact-tube-to-work distance (13, 19 and 25 mm), current, voltage, and wire feed rate on metal transfer. The droplet transfer modes were identified for each map by both the sound of the arc and images from a laser back-lit high-speed video system. The modes were correlated to digital records of the voltage and current fluctuations. The maps contain detailed information on the spray transfer mode, including the boundaries of drop spray, streaming spray and rotating spray modes. The metal transfer modemore » boundaries shifted with an increase in contact-tube-to-work distance. Increasing the contact-tube-to-work distance from 13 to 19 mm resulted in a 15 mm/s increase in the wire feet rate for the globular-to-drop-spray transition.« less

Effect of layer thickness on the properties of nickel thermal sprayed steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nurisna, Zuhri, E-mail: zuhri-nurisna@yahoo.co.id; Triyono,, E-mail: triyonomesin@uns.ac.id; Muhayat, Nurul, E-mail: nurulmuhayat@staff.uns.ac.id

Thermal arc spray nickel coating is widely used for decorative and functional applications, by improving corrosion resistance, wear resistance, heat resistence or by modifying other properties of the coated materials. There are several properties have been studied. Layer thickness of nickel thermal sprayed steel may be make harder the substrate surface. In this study, the effect of layer thickness of nickel thermal sprayed steel has been investigated. The rectangular substrate specimens were coated by Ni–5 wt.% Al using wire arc spray method. The thickness of coating layers were in range from 0.4 to 1.0 mm. Different thickness of coating layers weremore » conducted to investigate their effect on hardness and morphology. The coating layer was examined by using microvickers and scanning electron microscope with EDX attachment. Generally, the hardness at the interface increased with increasing thickness of coating layers for all specimens due to higher heat input during spraying process. Morphology analysis result that during spraying process aluminum would react with surrounding oxygen and form aluminum oxide at outer surface of splat. Moreover, porosity was formed in coating layers. However, presence porosity is not related to thickness of coating material. The thicker coating layer resulted highesr of hardness and bond strength.« less

Selecting Processes to Minimize Hexavalent Chromium from Stainless Steel Welding

PubMed Central

KEANE, M.; SIERT, A.; STONE, S.; CHEN, B.; SLAVEN, J.; CUMPSTON, A.; ANTONINI, J.

2015-01-01

Eight welding processes/shielding gas combinations were assessed for generation of hexavalent chromium (Cr6+) in stainless steel welding fumes. The processes examined were gas metal arc welding (GMAW) (axial spray, short circuit, and pulsed spray modes), flux cored arc welding (FCAW), and shielded metal arc welding (SMAW). The Cr6+ fractions were measured in the fumes; fume generation rates, Cr6+ generation rates, and Cr6+ generation rates per unit mass of welding wire were determined. A limited controlled comparison study was done in a welding shop including SMAW, FCAW, and three GMAW methods. The processes studied were compared for costs, including relative labor costs. Results indicate the Cr6+ in the fume varied widely, from a low of 2800 to a high of 34,000 ppm. Generation rates of Cr6+ ranged from 69 to 7800 μg/min, and Cr6+ generation rates per unit of wire ranged from 1 to 270 μg/g. The results of field study were similar to the findings in the laboratory. The Cr6+ (ppm) in the fume did not necessarily correlate with the Cr6+ generation rate. Physical properties were similar for the processes, with mass median aerodynamic diameters ranging from 250 to 336 nm, while the FCAW and SMAW fumes were larger (360 and 670 nm, respectively). Conclusion: The pulsed axial spray method was the best choice of the processes studied based on minimal fume generation, minimal Cr6+ generation, and cost per weld. This method is usable in any position, has a high metal deposition rate, and is relatively simple to learn and use. PMID:26690276

Spray Characteristics and Tribo-Mechanical Properties of High-Velocity Arc-Sprayed WC-W2C Iron-Based Coatings

NASA Astrophysics Data System (ADS)

Tillmann, W.; Hagen, L.; Kokalj, D.

2017-10-01

In terms of arc-sprayed coatings, the lamellar coating microstructure is mainly affected by the atomization behavior of the molten electrode tips. When using compressed air, oxide formations occur during atomization, across the particle-laden spray plume and when the molten droplets splash onto the substrate. Within the scope of this study, the potential of a high-velocity arc-spraying process due to elevated atomization gas pressures and its effect on the spray and coating characteristics was analyzed using a cast tungsten carbide (CTC)-reinforced FeCMnSi cored wire. Since the atomization behavior corresponds with the electrode phenomena, the power spectrum and the droplet formation were observed during spraying. The tribo-mechanical properties of CTC-FeCMnSi coatings were examined in dry sliding experiments and indentation tests. In addition, adhesion tests and metallographic investigations were carried out to analyze the bonding strength, cohesive behavior, and lamellar microstructure. The occurrence of oxide phases was evaluated by x-ray diffraction and electron microscopy. Moreover, the oxygen content was determined by using glow discharge optical emission spectroscopy as well as energy-dispersive x-ray spectroscopy. With respect to elevated atomization gas pressures, a dense microstructure with improved adhesion to the substrate and reduced surface roughness was observed. Dry sliding experiments revealed an advanced wear behavior of specimens, when using above average increased atomization gas pressures. Analytic methods verified the existence of oxide phases, which were generated during spraying. A significant change of the extent and type of oxides, when applying an increased flow rate of the atomization gas, cannot be observed. Besides an enhanced coating quality, the use of increased atomization gas pressure exhibited good process stability.

The shear strength of three-dimensional capillary-porous titanium coatings for intraosseous implants.

PubMed

Kalita, V I; Komlev, D I; Komlev, V S; Radyuk, A A

2016-03-01

A plasma spraying process for the deposition of three-dimensional capillary-porous titanium coatings using a wire has been developed. In this process, two additional dc arcs are discharged between plasmatron and both the wire and the substrate, resulting in additional activation of the substrate and the particles, particularly by increasing their temperature. The shear strength of the titanium coating with 46% porosity is 120.6 MPa. A new procedure for estimating the shear strength of porous coatings has been developed. Copyright © 2015 Elsevier B.V. All rights reserved.

Selecting Processes to Minimize Hexavalent Chromium from Stainless Steel Welding: Eight welding processes/shielding gas combinations were assessed for generation of hexavalent chromium in stainless steel welding fumes.

PubMed

Keane, M; Siert, A; Stone, S; Chen, B; Slaven, J; Cumpston, A; Antonini, J

2012-09-01

Eight welding processes/shielding gas combinations were assessed for generation of hexavalent chromium (Cr 6+ ) in stainless steel welding fumes. The processes examined were gas metal arc welding (GMAW) (axial spray, short circuit, and pulsed spray modes), flux cored arc welding (FCAW), and shielded metal arc welding (SMAW). The Cr 6+ fractions were measured in the fumes; fume generation rates, Cr 6+ generation rates, and Cr 6+ generation rates per unit mass of welding wire were determined. A limited controlled comparison study was done in a welding shop including SMAW, FCAW, and three GMAW methods. The processes studied were compared for costs, including relative labor costs. Results indicate the Cr 6+ in the fume varied widely, from a low of 2800 to a high of 34,000 ppm. Generation rates of Cr 6+ ranged from 69 to 7800 μg/min, and Cr 6+ generation rates per unit of wire ranged from 1 to 270 μg/g. The results of field study were similar to the findings in the laboratory. The Cr 6+ (ppm) in the fume did not necessarily correlate with the Cr 6+ generation rate. Physical properties were similar for the processes, with mass median aerodynamic diameters ranging from 250 to 336 nm, while the FCAW and SMAW fumes were larger (360 and 670 nm, respectively). The pulsed axial spray method was the best choice of the processes studied based on minimal fume generation, minimal Cr 6+ generation, and cost per weld. This method is usable in any position, has a high metal deposition rate, and is relatively simple to learn and use.

Laser Assisted Micro Wire GMAW and Droplet Welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

FUERSCHBACH, PHILLIP W.; LUCK, D. L.; BERTRAM, LEE A.

2002-03-01

Laser beam welding is the principal welding process for the joining of Sandia weapon components because it can provide a small fusion zone with low overall heating. Improved process robustness is desired since laser energy absorption is extremely sensitive to joint variation and filler metal is seldom added. This project investigated the experimental and theoretical advantages of combining a fiber optic delivered Nd:YAG laser with a miniaturized GMAW system. Consistent gas metal arc droplet transfer employing a 0.25 mm diameter wire was only obtained at high currents in the spray transfer mode. Excessive heating of the workpiece in this modemore » was considered an impractical result for most Sandia micro-welding applications. Several additional droplet detachment approaches were investigated and analyzed including pulsed tungsten arc transfer(droplet welding), servo accelerated transfer, servo dip transfer, and electromechanically braked transfer. Experimental observations and rigorous analysis of these approaches indicate that decoupling droplet detachment from the arc melting process is warranted and may someday be practical.« less

Hot Corrosion Behavior of Arc-Sprayed Highly Dense NiCr-Based Coatings in Chloride Salt Deposit

NASA Astrophysics Data System (ADS)

Qin, Enwei; Yin, Song; Ji, Hua; Huang, Qian; Liu, Zekun; Wu, Shuhui

2017-04-01

To make cities more environmentally friendly, combustible wastes tend to be incinerated in waste-to-energy power plant boilers. However, release of chlorine gas (Cl2) during incineration causes serious problems related to hot corrosion of boiler tubes and poses a safety threat for such plants. In this study, a pseudo-de Laval nozzle was employed in a twin-wire arc spray system to enhance the velocity of in-flight particles. Highly dense NiCr-based coatings were obtained using the modified nozzle gun. The coating morphology was characterized by optical microscopy and scanning electron microscopy, and hot corrosion testing was carried out in a synthetic molten chloride salt environment. Results showed that the dense NiCr-based coatings exhibited high resistance against corrosion by chlorine, which can be related to the typical splat lamellar microstructure and chemical composition as well as minor alloying elements such as Ti and Mo.

Spray pattern analysis in TWAS using photogrammetry and digital image correlation

NASA Astrophysics Data System (ADS)

Tillmann, W.; Rademacher, H. G.; Hagen, L.; Abdulgader, M.; El Barad’ei, M.

2018-06-01

In terms of arc spraying processes, the spray plume characteristic is mainly affected by the flow characteristic of the atomization gas at the nozzle inlet and intersection point of the wire tips, which in turn affect the particle distribution at the moment of impact when molten spray particles splash onto the substrate. With respect to the route of manufacturing of near net-shaped coatings on complex geometries, the acquisition of the spray patterns is pressingly necessary to determine the produced coating thickness. Within the scope of this study, computer fluid dynamics (CFD) simulations were carried out to determine the distribution of spray particles for different spray parameter settings. The results were evaluated by three-dimensional spray spot analyses using an optical measurement based on photogrammetry and digital image correlation. The optical measurement represents a promising and much faster candidate to measure spray patterns compared to the tactile measurement system but with an equal accuracy. For given nozzle configurations and spray parameter settings, numerous spray patterns were examined to their shape factors, demonstrating the potential of an online analysis, which encompasses a “fast sample loop” and a data processing system to generate a three-dimensional surface of the spray spot profile.

An Alternative Cu-Based Bond Layer for Electric Arc Coating Process

NASA Astrophysics Data System (ADS)

Fadragas, Carlos R.; Morales, E. V.; Muñoz, J. A.; Bott, I. S.; Lariot Sánchez, C. A.

2011-12-01

A Cu-Al alloy has been used as bond coat between a carbon steel substrate and a final coating deposit obtained by applying the twin wire electric arc spraying coating technique. The presence of a copper-based material in the composite system can change the overall temperature profile during deposition because copper exhibits a thermal conductivity several times higher than that of the normally recommended bond coat materials (such as nickel-aluminum alloys or nickel-chromium alloys). The microstructures of 420 and 304 stainless steels deposited by the electric arc spray process have been investigated, focusing attention on the deposit homogeneity, porosity, lamellar structure, and microhardness. The nature of the local temperature gradient during deposition can strongly influence the formation of the final coating deposit. This study presents a preliminary study, undertaken to investigate the changes in the temperature profile which occur when a Cu-Al alloy is used as bond coat, and the possible consequences of these changes on the microstructure and adhesion of the final coating deposit. The influence of the thickness of the bond layer on the top coating temperature has also been also evaluated.

Spray process for in situ synthesizing Ti(C,N)-TiB2-Al2O3 composite ceramic coatings

NASA Astrophysics Data System (ADS)

Zhou, Jian; Liu, Hongwei; Sun, Sihao

2017-12-01

Using core wires with Ti-B4C-C as core and Al as strip materials, Ti(C,N)-TiB2-Al2O3 composite ceramic coatings were prepared on 45 steel substrates by the reactive arc spray technology. The influence of spray voltage, current, gas pressure and distance on the coatings was discussed. The spray parameters were optimized with porosity of the coatings as evaluation standard. The results showed that the most important factor which influences the quality of the coatings was spray distance. Then spray gas pressure, current and voltage followed in turn. The optimum process was spray current of 120A, voltage of 36, gas pressure of 0.7MPa and distance of 160mm. The porosity of coatings prepared in this spray process was only 2.11%. The coatings were composed of TiB2, TiC0.3N0.7, TiN, Al2O3 and AlN. Good properties and uniform distribution of these ceramic phases made the coatings have excellent comprehensive performances.

Quality Designed Twin Wire Arc Spraying of Aluminum Bores

NASA Astrophysics Data System (ADS)

König, Johannes; Lahres, Michael; Methner, Oliver

2015-01-01

After 125 years of development in combustion engines, the attractiveness of these powerplants still gains a great deal of attention. The efficiency of engines has been increased continuously through numerous innovations during the last years. Especially in the field of motor engineering, consequent friction optimization leads to cost-effective fuel consumption advantages and a CO2 reduction. This is the motivation and adjusting lever of NANOSLIDE® from Mercedes-Benz. The twin wire arc-spraying process of the aluminum bore creates a thin, iron-carbon-alloyed coating which is surface-finished through honing. Due to the continuous development in engines, the coating strategies must be adapted in parallel to achieve a quality-conformed coating result. The most important factors to this end are the controlled indemnification of a minimal coating thickness and a homogeneous coating deposition of the complete bore. A specific system enables the measuring and adjusting of the part and the central plunging of the coating torch into the bore to achieve a homogeneous coating thickness. Before and after measurement of the bore diameter enables conclusions about the coating thickness. A software tool specifically developed for coating deposition can transfer this information to a model that predicts the coating deposition as a function of the coating strategy.

Feasibility Study for Casting of High Temperature Refractory Superalloy Composites

NASA Technical Reports Server (NTRS)

Lee, Jonathan A.

1998-01-01

Abstract This study investigated the feasibility of using conventional casting technique to fabricate refractory wires reinforced superalloy composites. These composites were being developed for advanced rocket engine turbine blades and other high temperature applications operating up to 2000 F. Several types of refractory metal wires such as W- Th, W-Re, Mo-Hf-C and W-HF-C reinforced waspaloy were experimentally cast and heat treated at 2000 F up to 48 hrs. Scanning electron microscope analysis was conducted in regions adjacent to the wire-matrix interface to determine the reaction zone and chemical compatibility resulting from material interdiffusion. It was concluded that fabrication using conventional casting may be feasible because the wire-matrix reaction zone thickness was comparable to similar composites produced by arc-sprayed monotape with hot isostatic pressing technique, Moreover, it was also found that the chemical compatibility could be improved significantly through a slight modification of the superalloy matrix compositions.

Thermally Sprayed High Temperature Sandwich Structures: Physical Properties and Mechanical Performance

NASA Astrophysics Data System (ADS)

Salavati, Saeid

Metallic foam core sandwich structures have been of particular interest for engineering applications in recent decades due to their unique physical and mechanical properties. One of the potential applications of open pore metallic foam core sandwich structures is in heat exchangers. An investigation of sandwich structures fabricated from materials suitable for application at high temperatures and in corrosive environments was undertaken in this project. A novel method for fabrication of metallic foam core sandwich structures is thermal spray deposition of the faces on the prepared surfaces of the metallic foam substrate. The objective of the current study was to optimize the twin wire arc spray process parameters for the deposition of alloy 625 faces with controllable porosity content on the nickel foam substrate, and to characterize the physical and mechanical properties of the sandwich structure. The experimental investigations consisted of microstructural evaluation of the skin material and the foam substrate, investigation of the effect of alloying on the mechanical and thermal properties of the nickel foam, optimization of the grit-blasting and arc spray processes, observation of mechanical properties of the alloy 625 deposit by tensile testing and evaluation of the overall mechanical properties of the sandwich structure under flexural loading condition. The optimization of arc spraying process parameters allowed deposition of alloy 625 faces with a porosity of less than 4% for heat exchanger applications. Modification of the arc spraying process by co-deposition of polyester powder enabled 20% porosity to be obtained in the deposited faces for heat shield applications with film cooling. The effects of nickel foam alloying and heat treatment on the flexural rigidity of the sandwich structures were investigated and compared with as-received foam and as-fabricated sandwich structures. Available analytical models were employed to describe the effect of constituents' mechanical properties on the overall mechanical performance of the sandwich structures. Finite element modeling using ANSYS Structural was used to simulate the behaviour of the sandwich structures in four-point bending. The analytical and simulation results were compared with the experimental results obtained from the flexural tests.

Transfer of Wire Arc-Sprayed Metal Coatings onto Plastic Parts

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Knoch, M. A.; Liao, X.; Hopmann, Ch.; Ochotta, P.

2018-01-01

By means of In-Mold-Metal-Spraying (IMMS), metal coatings deposited by means of arc spraying process (ASP) can be transferred onto plastic parts during injection molding, thus realizing an efficient production of metallized plastic parts. Parts produced by means of IMMS can be used in electrical applications. In the current study, the electrical resistivity of coatings applied with different feedstock materials was determined. As a starting point, pressurized air is used as atomizing gas for ASP. In contrast to Zn coatings, Cu coatings applied with pressurized air exhibit a significantly higher electrical resistivity in comparison with massive material. One possible reason is the more pronounced oxidation of Cu particles during ASP. Therefore, N2 and a mixture of N2 and H2 were used as atomizing gas. As a result, the electrical resistivity of coatings applied by means of IMMS could be significantly reduced. Furthermore, standoff distance, current and pressure of the atomizing gas were varied to investigate the influence of these process parameters on the electrical resistivity of Zn coatings using a full factorial experiment design with center point. It can be observed that the electrical resistivity of the Zn coatings increases with decreasing current and increasing standoff distance and pressure.

Transfer of Wire Arc-Sprayed Metal Coatings onto Plastic Parts

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Knoch, M. A.; Liao, X.; Hopmann, Ch.; Ochotta, P.

2017-12-01

By means of In-Mold-Metal-Spraying (IMMS), metal coatings deposited by means of arc spraying process (ASP) can be transferred onto plastic parts during injection molding, thus realizing an efficient production of metallized plastic parts. Parts produced by means of IMMS can be used in electrical applications. In the current study, the electrical resistivity of coatings applied with different feedstock materials was determined. As a starting point, pressurized air is used as atomizing gas for ASP. In contrast to Zn coatings, Cu coatings applied with pressurized air exhibit a significantly higher electrical resistivity in comparison with massive material. One possible reason is the more pronounced oxidation of Cu particles during ASP. Therefore, N2 and a mixture of N2 and H2 were used as atomizing gas. As a result, the electrical resistivity of coatings applied by means of IMMS could be significantly reduced. Furthermore, standoff distance, current and pressure of the atomizing gas were varied to investigate the influence of these process parameters on the electrical resistivity of Zn coatings using a full factorial experiment design with center point. It can be observed that the electrical resistivity of the Zn coatings increases with decreasing current and increasing standoff distance and pressure.

Control of dispersed-phase temperature in plasma flows by the spectral-brightness pyrometry method

NASA Astrophysics Data System (ADS)

Dolmatov, A. V.; Gulyaev, I. P.; Gulyaev, P. Yu; Iordan, V. I.

2016-02-01

In the present work, we propose a new method for measuring the distribution of temperature in the ensembles of condensed-phase particles in plasma spray flows. Interrelation between the spectral temperature of the particles and the distribution of camera brightness signal is revealed. The established inter-relation enables an in-situ calibration of measuring instruments using the objects under study. The spectral-brightness pyrometry method was approbated on a Plazer plasma-arc wire spraying facility at the Paton Institute of Electrical Welding (Ukrainian Academy of Sciences, Kiev) and on the Thermoplasma 50-1 powder spraying facility at the Institute of Theoretical and Applied Mechanics (Russian Academy of Sciences, Siberian Branch, Novosibirsk). The work was supported by the Russian Foundation for Basic Research (Grants Nos. 14-08-90428 and 15-48-00100).

Plasma arc torch with coaxial wire feed

DOEpatents

Hooper, Frederick M

2002-01-01

A plasma arc welding apparatus having a coaxial wire feed. The apparatus includes a plasma arc welding torch, a wire guide disposed coaxially inside of the plasma arc welding torch, and a hollow non-consumable electrode. The coaxial wire guide feeds non-electrified filler wire through the tip of the hollow non-consumable electrode during plasma arc welding. Non-electrified filler wires as small as 0.010 inches can be used. This invention allows precision control of the positioning and feeding of the filler wire during plasma arc welding. Since the non-electrified filler wire is fed coaxially through the center of the plasma arc torch's electrode and nozzle, the wire is automatically aimed at the optimum point in the weld zone. Therefore, there is no need for additional equipment to position and feed the filler wire from the side before or during welding.

TAZ-8A Alloy Increases The Thermal Endurance Of Steel

NASA Technical Reports Server (NTRS)

Waters, William J.

1990-01-01

TAZ-8A exhibits high strength at temperatures as high as 1,400 degrees F (760 degrees C) and resistance to oxidation; also exhibits excellent cyclic shock resistance between 600 and 2,000 degrees F (316 and 1,093 degrees C) and superplasticity at 1,800 degrees F (982 degrees C). Converts into fine powder and then flame-, plasma-, arc-, or wire-sprayed onto inexpensive steel substrate. Surface treatment with this alloy prolongs service life and reduces costs.

In Situ Acoustic Monitoring of Thermal Spray Process Using High-Frequency Impulse Measurements

NASA Astrophysics Data System (ADS)

Tillmann, Wolfgang; Walther, Frank; Luo, Weifeng; Haack, Matthias; Nellesen, Jens; Knyazeva, Marina

2018-01-01

In order to guarantee their protective function, thermal spray coatings must be free from cracks, which expose the substrate surface to, e.g., corrosive media. Cracks in thermal spray coatings are usually formed because of tensile residual stresses. Most commonly, the crack occurrence is determined after the thermal spraying process by examination of metallographic cross sections of the coating. Recent efforts focus on in situ monitoring of crack formation by means of acoustic emission analysis. However, the acoustic signals related to crack propagation can be absorbed by the noise of the thermal spraying process. In this work, a high-frequency impulse measurement technique was applied to separate different acoustic sources by visualizing the characteristic signal of crack formation via quasi-real-time Fourier analysis. The investigations were carried out on a twin wire arc spraying process, utilizing FeCrBSi as a coating material. The impact of the process parameters on the acoustic emission spectrum was studied. Acoustic emission analysis enables to obtain global and integral information on the formed cracks. The coating morphology and coating defects were inspected using light microscopy on metallographic cross sections. Additionally, the resulting crack patterns were imaged in 3D by means of x-ray microtomography.

Pneumotoxicity and pulmonary clearance of different welding fumes after intratracheal instillation in the rat.

PubMed

Antonini, J M; Krishna Murthy, G G; Rogers, R A; Albert, R; Ulrich, G D; Brain, J D

1996-09-01

The objectives of this study were to compare different welding fumes in regard to their potential to elicit lung inflammation or injury and to examine possible mechanisms whereby welding fumes may damage the lungs. Fume was collected on filters from conventional spray [mild steel (MS-SPRAY) or stainless steel (SS-SPRAY) electrode wire] or pulsed current [mild steel (MS-PULSE) electrode wire] gas-shielded metal arc welding. Rats were given one of the three welding fume samples by intratracheal instillation (1.0 mg/100 g body wt). Other rats received a relatively inert dust (iron oxide), a pneumotoxic dust (crystalline silica), or a vehicle control (saline). Bronchoalveolar lavage (BAL) was performed 1, 7, 14, and 35 days postinstillation, and indicators of pulmonary damage [cellular differential, albumin, as well as, tumor necrosis factor-alpha (TNF-alpha), interleukin-1 beta (IL-1 beta), lactate dehydrogenase, and beta-n-acetyl glucosaminidase release] were assessed. One day postinstillation, some evidence of lung inflammation (more neutrophils) was observed for all particle groups, while increased BAL TNF-alpha and IL-1 beta were observed only in the SS-SPRAY and silica groups. By 14 days, lungs appeared normal among the MS-SPRAY, MS-PULSE, and iron oxide groups. At 14 and 35 days postinstillation, elevated pulmonary responses persisted for the animals exposed to silica and the SS-SPRAY welding fume. By 35 days, however, the SS-SPRAY group approached control levels, while the injury induced by silica increased. Using magnetometric estimates of welding fumes, we observed that MS-SPRAY fume was cleared from the lungs at a faster rate than the SS-SPRAY particles. We have demonstrated that the SS-SPRAY fume has more pneumotoxicity than MS fumes. This difference may reflect a greater retention of the SS-SPRAY particles in the lungs and different elemental composition of the fume. The SS-SPRAY fume also had enhanced release of TNF-alpha and IL-1 beta from lung cells soon after fume instillation. In contrast, we saw no influence of the power supply on particle size, composition, or toxicity.

Environmental Influence of Gravity and Pressure on Arc Tracking of Insulated Wires Investigated

NASA Technical Reports Server (NTRS)

2005-01-01

Momentary short-circuit arcs between a defective polyimide-insulated wire and another conductor may thermally char (pyrolize) the insulating material. The charred polyimide, being conductive, can sustain the short-circuit arc, which may propagate along the wire through continuous pyrolization of the polyimide insulation (arc tracking). If the arcing wire is part of a multiple-wire bundle, the polyimide insulation of other wires within the bundle may become thermally charred and start arc tracking also (flash over). Such arc tracking can lead to complete failure of an entire wire bundle, causing other critical spacecraft or aircraft failures. Unfortunately, all tested candidate wire insulations for aerospace vehicles were susceptible to arc tracking. Therefore, a test procedure was designed at the NASA Lewis Research Center to select the insulation type least susceptible to arc tracking. This test procedure addresses the following three areas of concern: (1) probability of initiation, (2) probability of reinitiation (restrike), and (3) extent of arc tracking damage (propagation rate). Item 2 (restrike probability) is an issue if power can be terminated from and reapplied to the arcing wire (by a switch, fuse, or resettable circuit breaker). The degree of damage from an arcing event (item 3) refers to how easily the arc chars nearby insulation and propagates along the wire pair. Ease of nearby insulation charring can be determined by measuring the rate of arc propagation. Insulation that chars easily will propagate the arc faster than insulation that does not char very easily. A popular polyimide insulated wire for aerospace vehicles, MIL-W-81381, was tested to determine a degree of damage from an arcing event (item 3) in the following three environments: (1) microgravity with air at 1-atm pressure, (2) 1g with air at 1 atm, and (3) 1g within a 10^-6 Torr vacuum. The microgravity 1-atm air was the harshest environment, with respect to the rate of damage of arc tracking, for the 20 AWG (American Wiring Gauge) MIL-W-81381 wire insulation type . The vacuum environment resulted in the least damage. Further testing is planned to determine if the environmental results are consistent between insulation types and to evaluate the other two parameters associated with arc tracking susceptibility.

Influence of Mode of Metal Transfer on Microstructure and Mechanical Properties of Gas Metal Arc-Welded Modified Ferritic Stainless Steel

NASA Astrophysics Data System (ADS)

Mukherjee, Manidipto; Pal, Tapan Kumar

2012-06-01

This article describes in detail the effect of the modes of metal transfer on the microstructure and mechanical properties of gas metal arc-welded modified ferritic stainless steel (SSP 409M) sheets (as received) of 4 mm thickness. The welded joints were prepared under three modes of metal transfer, i.e., short-circuit (SC), spray (S), transfer, and mix (M) mode transfer using two different austenitic filler wires (308L and 316L) and shielding gas composition of Ar + 5 pct CO2. The welded joints were evaluated by means of microstructural, hardness, notched tensile strength, Charpy impact toughness, and high cycle fatigue. The dependence of weld metal microstructure on modes of metal transfer and filler wires has been determined by dilution calculation, WRC-1992 diagram, Creq/Nieq ratio, stacking fault energy (SFE), optical microscopy (OM), and transmission electron microscopy (TEM). It was observed that the microstructure as well as the tensile, Charpy impact, and high cycle fatigue of weld metal is significantly affected by the mode of metal transfer and filler wire used. However, the heat-affected zone (HAZ) is affected only by the modes of metal transfer. The results have been correlated with the microstructures of weld and HAZ developed under different modes of metal transfer.

Comparison of Arc Tracking Tests in Various Aerospace Environments

NASA Technical Reports Server (NTRS)

Stueber, Thomas J.; Hammoud, Ahmad; McCall, David

1996-01-01

Momentary short-circuit arcs between a polyimide insulated wire with defective insulation and another conductor may cause pyrolization of the insulation resulting in a conductive path capable of sustaining the arc. These sustained arcs may propagate along the wires or to neighboring wires leading to complete failure of the wire bundle. Wire insulation susceptibility to arc tracking may be dependent on its environment. Because all wire insulation types tested to date arc track, a test procedure has been developed to compare different insulation types with respect to their arc tracking susceptibility. This test procedure is presented along with a comparison of arc tracking in the following three environments: (1) Air at atmospheric pressure and 1 gravitational(g) force; (2) Vacuum (2.67 x 10(exp -3) Pa) and 1g, and (3) Air at atmospheric pressure and microgravity (less than 0.04g).

Dry and wet arc track propagation resistance testing

NASA Technical Reports Server (NTRS)

Beach, Rex

1995-01-01

The wet arc-propagation resistance test for wire insulation provides an assessment of the ability of an insulation to prevent damage in an electrical environment. Results of an arc-propagation test may vary slightly due to the method of arc initiation; therefore a standard test method must be selected to evaluate the general arc-propagation resistance characteristics of an insulation. This test method initiates an arc by dripping salt water over pre-damaged wires which creates a conductive path between the wires. The power supply, test current, circuit resistances, and other variables are optimized for testing 20 guage wires. The use of other wire sizes may require modifications to the test variables. The dry arc-propagation resistance test for wire insulation also provides an assessment of the ability of an insulation to prevent damage in an electrical arc environment. In service, electrical arcs may originate form a variety of factors including insulation deterioration, faulty installation, and chafing. Here too, a standard test method must be selected to evaluate the general arc-propagation resistance characteristics of an insulation. This test method initiates an arc with a vibrating blade. The test also evaluates the ability of the insulation to prevent further arc-propagation when the electrical arc is re-energized.

Thermal Arc Spray Overview

NASA Astrophysics Data System (ADS)

Hafiz Abd Malek, Muhamad; Hayati Saad, Nor; Kiyai Abas, Sunhaji; Mohd Shah, Noriyati

2013-06-01

Usage of protective coating for corrosion protection was on highly demand during the past decade; and thermal spray coating played a major part during that time. In recent years, the thermal arc spray coating becomes a popular coating. Many big players in oil and gas such as PETRONAS, EXXON MOBIL and SHELL in Malaysia tend to use the coating on steel structure as a corrosion protection. Further developments in coating processes, the devices, and raw materials have led to expansion of functional coatings and applications scope from conventional coating to specialized industries. It is widely used because of its ability to withstand high process temperature, offer advantages in efficiency, lower cost and acts as a corrosion protection. Previous research also indicated that the thermal arc spray offers better coating properties compared to other methods of spray. This paper reviews some critical area of thermal spray coating by discussing the process/parameter of thermal arc spray technology and quality control of coating. Coating performance against corrosion, wear and special characteristic of coating are also described. The field application of arc spray technology are demonstrated and reviewed.

Evaluation of pyrolysis and arc tracking on candidate wire insulation designs for space applications

NASA Astrophysics Data System (ADS)

Stueber, Thomas J.; Hammoud, Ahmad; Stavnes, Mark W.; Hrovat, Kenneth

1994-05-01

Polyimide wire insulation has been found to be vulnerable to pyrolization and arc tracking due to momentary short circuit arcing events. This report compares arc tracking susceptibility of candidate insulation configurations for space wiring applications. The insulation types studied in this report were gauge 20 (0.81 mm dia.) hybrid wiring constructions using polyimide, tetrafluoroethylene (TFE), cross-linked ethylene tetrafluoroethylene (XL-ETFE) and/or polytetrafluoroethylene (PTFE) insulations. These constructions were manufactured according to military wiring standards for aerospace applications. Arc track testing was conducted under DC bias and vacuum (10(exp -6) torr). The tests were conducted to compare the various insulation constructions in terms of their resistance to arc tracking restrike. The results of the tests are presented.

29 CFR 1917.153 - Spray painting (See also § 1917.2, definition of Hazardous cargo, materials, substance, or...

Code of Federal Regulations, 2010 CFR

2010-07-01

... accumulate on electrical installations, wiring shall be in rigid conduit or in boxes containing no taps... pressure. (12) Wiring, motors and equipment in a spray booth shall be of approved explosion-proof type for..., Hazardous Locations. Wiring, motors and equipment within 20 feet (6.1m) of any interior spraying area and...

Effects of laser remelting on microstructures and immersion corrosion performance of arc sprayed Al coating in 3.5% NaCl solution

NASA Astrophysics Data System (ADS)

Sun, Ze; Zhang, Donghui; Yan, Baoxu; Kong, Dejun

2018-02-01

An arc sprayed aluminum (Al) coating on S355 steel was processed using a laser remelting (LR). The microstructures, chemical element composition, and phases of the obtained Al coating were analyzed using a field mission scanning electronic microscope (FESEM), energy dispersive spectrometer (EDS), and X-ray diffractometer (XRD), respectively, and the residual stresses were measured using an X-ray diffraction stress tester. The immersion corrosion tests and potentiodynamic polarization of Al coating in 3.5% NaCl solution were performed to investigate the effects of LR on its immersion corrosion behaviors, and the corrosion mechanism of Al coating was also discussed. The results show that the arc sprayed Al coating is composed of Al phase, while that by LR is composed of Al-Fe and AlO4FeO6 phases, and the porosities and cracks in the arc sprayed Al coating are eliminated by LR, The residual stress of arc sprayed Al coating is -5.6 ± 18 MPa, while that after LR is 137.9 ± 12 MPa, which deduces the immersion corrosion resistance of Al coating. The corrosion mechanism of arc sprayed Al coating is pitting corrosion and crevice corrosion, while that by LR is uniform corrosion and pitting corrosion. The corrosion potential of arc sprayed Al coating by LR shifts positively, which improves its immersion corrosion resistance.

NASA requirements and applications environments for electrical power wiring

NASA Technical Reports Server (NTRS)

Stavnes, Mark W.; Hammoud, Ahmad N.

1992-01-01

Serious problems can occur from insulation failures in the wiring harnesses of aerospace vehicles. In most recorded incidents, the failures have been identified to be the result of arc tracking, the propagation of an arc along wiring bundles through degradation of insulation. Propagation of the arc can lead to the loss of the entire wiring harness and the functions which it supports. While an extensive database of testing for arc track resistant wire insulations has been developed for aircraft applications, the counterpart requirements for spacecraft are very limited. The electrical, thermal, mechanical, chemical, and operational requirements for specification and testing of candidate wiring systems for spacecraft applications is presented.

An advanced arc track resistant airframe wire

NASA Technical Reports Server (NTRS)

Beatty, J.

1995-01-01

Tensolite, a custom cable manufacturer specializing in high temperature materials as the dielectric medium, develops an advance arc track resistant airframe wire called Tufflite 2000. Tufflite 2000 has the following advantages over the other traditional wires: lighter weight and smaller in diameter; excellent wet and dry arc track resistance; superior dynamic cut-through performance even at elevated temperatures; flight proven performance on Boeing 737 and 757 airplanes; and true 260 C performance by utilizing Nickel plated copper conductors. This paper reports the different tests performed on Tufflite 2000: accelerated aging, arc resistance (wet and dry), dynamic cut through, humidity resistance, wire-to-wire abrasion, flammability, smoke, weight, notch sensitivity, flexibility, and markability. It particularly focuses on the BSI (British Standards Institute) dry arc resistance test and BSI wet arc tracking.

A demonstration of the antimicrobial effectiveness of various copper surfaces

PubMed Central

2013-01-01

Background Bacterial contamination on touch surfaces results in increased risk of infection. In the last few decades, work has been done on the antimicrobial properties of copper and its alloys against a range of micro-organisms threatening public health in food processing, healthcare and air conditioning applications; however, an optimum copper method of surface deposition and mass structure has not been identified. Results A proof-of-concept study of the disinfection effectiveness of three copper surfaces was performed. The surfaces were produced by the deposition of copper using three methods of thermal spray, namely, plasma spray, wire arc spray and cold spray The surfaces were then inoculated with meticillin-resistant Staphylococcus aureus (MRSA). After a two hour exposure to the surfaces, the surviving MRSA were assayed and the results compared. The differences in the copper depositions produced by the three thermal spray methods were examined in order to explain the mechanism that causes the observed differences in MRSA killing efficiencies. The cold spray deposition method was significantly more effective than the other methods. It was determined that work hardening caused by the high velocity particle impacts created by the cold spray technique results in a copper microstructure that enhances ionic diffusion, and copper ions are principally responsible for antimicrobial activity. Conclusions This test showed significant microbiologic differences between coatings produced by different spray techniques and demonstrates the importance of the copper application technique. The cold spray technique shows superior anti-microbial effectiveness caused by the high impact velocity imparted to the sprayed particles which results in high dislocation density and high ionic diffusivity. PMID:23537176

Plasma sprayed coatings on crankshaft used steels

NASA Astrophysics Data System (ADS)

Mahu, G.; Munteanu, C.; Istrate, B.; Benchea, M.

2017-08-01

Plasma spray coatings may be an alternative to conventional heat treatment of main journals and crankpins of the crankshaft. The applications of plasma coatings are various and present multiple advantages compared to electric arc wire spraying or flame spraying. The study examines the layers sprayed with the following powders: Cr3C2- 25(Ni 20Cr), Al2O3- 13TiO2, Cr2O3-SiO2- TiO2 on the surface of steels used in the construction of a crankshaft (C45). The plasma spray coatings were made with the Spray wizard 9MCE facility at atmospheric pressure. The samples were analyzed in terms of micro and morphological using optical microscopy, scanning electron microscopy and X-ray diffraction. Wear tests on samples that have undergone simulates extreme working conditions of the crankshafts. In order to emphasize adherence to the base material sprayed layer, were carried out tests of microscratches and micro-indentation. Results have showed a relatively compact morphological aspect given by the successive coatings with splat-like specific structures. Following the microscratch analysis it can be concluded that Al2O3-13TiO2 coating has a higher purpose in terms of hardness compared to Cr3C2-(Ni 20Cr) and Cr2O3-SiO2- TiO2 powders. Thermal coatings of the deposited powders have increased the mechanical properties of the material. The results stand to confirm that plasma sprayed Al2O3-13TiO2 powder is in fact a efficient solution for preventing mechanical wear, even with a faulty lubrication system.

Thermally sprayed prepregs for thixoforging of UD fiber reinforced light metal MMCs

NASA Astrophysics Data System (ADS)

Silber, Martin; Wenzelburger, Martin; Gadow, Rainer

2007-04-01

Low density and good mechanical properties are the basic requirements for lightweight structures in automotive and aerospace applications. With their high specific strength and strain to failure values, aluminum alloys could be used for such applications. Only the insufficient stiffness and thermal and fatigue strength prevented their usage in high-end applications. One possibility to solve this problem is to reinforce the light metal with unidirectional fibers. The UD fiber allows tailoring of the reinforcement to meet the direction of the component's load. In this study, the production of thermally sprayed prepregs for the manufacturing of continuous fiber reinforced MMC by thixoforging is analysed. The main aim is to optimize the winding procedure, which determines the fiber strand position and tension during the coating process. A method to wind and to coat the continuous fibers with an easy-to-use handling technique for the whole manufacturing process is presented. The prepregs were manufactured by producing arc wire sprayed AlSi6 coatings on fibers bundles. First results of bending experiments showed appropriate mechanical properties.

Interface characterization of Cu-Mo coating deposited on Ti-Al alloys by arc spraying

NASA Astrophysics Data System (ADS)

Bai, Shengqiang; Li, Fei; Wu, Ting; Yin, Xianglin; Shi, Xun; Chen, Lidong

2015-03-01

Cu-Mo pseudobinary alloys are promising candidates as electrode materials in CoSb3-based skutterudite thermoelectric (TE) devices for TE power generation. In this study, Cu-Mo coatings were deposited onto Ti-Al substrates by applying a dual-wire electric arc spraying coating technique. The microstructure of the surfaces, cross sections and coating interfaces were analyzed by scanning electron microscopy (SEM) and energy dispersion spectrometry (EDS). Cu-Mo coatings showed a typical banded splat with compact microstructures, and have no coarse pores nor micro-cracks. The thermal shock resistance of the Cu-Mo coating was also investigated to show good combinations with Ti-Al substrates. After 50 thermal shock cycles, there were no cracks observed at the interface. In contrast, the test of the thermal shock resistance of the Cu coating on the Ti-Al substrate was also investigated. Due to a large difference in the thermal expansion coefficients between Cu and Ti-Al alloys, the Cu coating flaked from the Ti-Al substrate completely after 10 thermal shock cycles. The contact resistivity of the Ti-Al/Cu-Mo interface was about 1.6 μΩṡcm2 and this value was unchanged after 50 thermal shock cycles, indicating the low electric resistance and high thermal stability of the Cu-Mo/Ti-Al interface.

Evaluation of Kapton pyrolysis, arc tracking, and arc propagation on the Space Station Freedom (SSF) solar array Flexible Current Carrier (FCC)

NASA Technical Reports Server (NTRS)

Stueber, Thomas J.

1991-01-01

Recent studies involving the use of polyimide Kapton coated wires indicate that if a momentary electrical short circuit occurs between two wires, sufficient heating of the Kapton can occur to thermally char (pyrolyze) the Kapton. Such charred Kapton has sufficient electrical conductivity to create an arc which tracks down the wires and possibly propagates to adjoining wires. These studies prompted an investigation to ascertain the likelihood of the Kapton pyrolysis, arc tracking and propagation phenomena, and the magnitude of destruction conceivably inflicted on Space Station Freedom's (SSF) Flexible Current Carrier (FCC) for the photovoltaic array. The geometric layout of the FCC, having a planar-type orientation as opposed to bundles, may reduce the probability of sustaining an arc. An experimental investigation was conducted to simulate conditions under which an arc can occur on the FCC of SSF, and the consequences of arc initiation.

Evaluation of Kapton pyrolysis, arc tracking, and arc propagation on the Space Station Freedom (SSF) solar array flexible current carrier (FCC)

NASA Technical Reports Server (NTRS)

Stueber, Thomas J.

1991-01-01

Recent studies involving the use of polyimide Kapton coated wires indicate that if a momentary electrical short circuit occurs between two wires, sufficient heating of the Kapton can occur to themally chlar (pyrolyze) the Kapton. Such charred Kapton has sufficient electricxl conductivity to create an arc which tracks down the wires and possibly propagates to adjoining wires. These studies prompted an invetigation to ascertain the likelihood of Kapton pyrolysis, arc tracking and propagation phenomena, and the magnitude of destruction conceivably inflicted on Space Station Freedom's (SSF's) Flexible Current Carrier (FCC) for the photovoltaic array. The geometric layout of the FCC, having a planar-type orientation as opposed to bundles, may reduce the probability of sustaining an arc. An experimental investigation was conducted to simulate conditions under which an arc can occur on the FCC of the SSF, and the consequences of arc initiation.

Modelling of gas-metal arc welding taking into account metal vapour

NASA Astrophysics Data System (ADS)

Schnick, M.; Fuessel, U.; Hertel, M.; Haessler, M.; Spille-Kohoff, A.; Murphy, A. B.

2010-11-01

The most advanced numerical models of gas-metal arc welding (GMAW) neglect vaporization of metal, and assume an argon atmosphere for the arc region, as is also common practice for models of gas-tungsten arc welding (GTAW). These models predict temperatures above 20 000 K and a temperature distribution similar to GTAW arcs. However, spectroscopic temperature measurements in GMAW arcs demonstrate much lower arc temperatures. In contrast to measurements of GTAW arcs, they have shown the presence of a central local minimum of the radial temperature distribution. This paper presents a GMAW model that takes into account metal vapour and that is able to predict the local central minimum in the radial distributions of temperature and electric current density. The influence of different values for the net radiative emission coefficient of iron vapour, which vary by up to a factor of hundred, is examined. It is shown that these net emission coefficients cause differences in the magnitudes, but not in the overall trends, of the radial distribution of temperature and current density. Further, the influence of the metal vaporization rate is investigated. We present evidence that, for higher vaporization rates, the central flow velocity inside the arc is decreased and can even change direction so that it is directed from the workpiece towards the wire, although the outer plasma flow is still directed towards the workpiece. In support of this thesis, we have attempted to reproduce the measurements of Zielińska et al for spray-transfer mode GMAW numerically, and have obtained reasonable agreement.

Evaluation of Kapton pyrolysis, arc tracking, and flashover on SiO(x)-coated polyimide insulated samples of flat flexible current carriers for Space Station Freedom

NASA Technical Reports Server (NTRS)

Stueber, Thomas J.; Mundson, Chris

1993-01-01

Kapton polyimide wiring insulation was found to be vulnerable to pyrolization, arc tracking, and flashover when momentary short-circuit arcs have occurred on aircraft power systems. Short-circuit arcs between wire pairs can pyrolize the polyimide resulting in a conductive char between conductors that may sustain the arc (arc tracking). Furthermore, the arc tracking may spread (flashover) to other wire pairs within a wire bundle. Polyimide Kapton will also be used as the insulating material for the flexible current carrier (FCC) of Space Station Freedom (SSF). The FCC, with conductors in a planar type geometric layout as opposed to bundles, is known to sustain arc tracking at proposed SSF power levels. Tests were conducted in a vacuum bell jar that was designed to conduct polyimide pyrolysis, arc tracking, and flashover studies on samples of SSF's FCC. Test results will be reported concerning the minimal power level needed to sustain arc tracking and the FCC susceptibility to flashover. Results of the FCC arc tracking tests indicate that only 22 volt amps were necessary to sustain arc tracking (proposed SSF power level is 400 watts). FCC flashover studies indicate that the flashover event is highly unlikely.

Evaluation Of Risk And Possible Mitigation Schemes For Previously Unidentified Hazards

NASA Technical Reports Server (NTRS)

Linzey, William; McCutchan, Micah; Traskos, Michael; Gilbrech, Richard; Cherney, Robert; Slenski, George; Thomas, Walter, III

2006-01-01

This report presents the results of arc track testing conducted to determine if such a transfer of power to un-energized wires is possible and/or likely during an arcing event, and to evaluate an array of protection schemes that may significantly reduce the possibility of such a transfer. The results of these experiments may be useful for determining the level of protection necessary to guard against spurious voltage and current being applied to safety critical circuits. It was not the purpose of these experiments to determine the probability of the initiation of an arc track event only if an initiation did occur could it cause the undesired event: an inadvertent thruster firing. The primary wire insulation used in the Orbiter is aromatic polyimide, or Kapton , a construction known to arc track under certain conditions [3]. Previous Boeing testing has shown that arc tracks can initiate in aromatic polyimide insulated 28 volts direct current (VDC) power circuits using more realistic techniques such as chafing with an aluminum blade (simulating the corner of an avionics box or lip of a wire tray), or vibration of an aluminum plate against a wire bundle [4]. Therefore, an arc initiation technique was chosen that provided a reliable and consistent technique of starting the arc and not a realistic simulation of a scenario on the vehicle. Once an arc is initiated, the current, power and propagation characteristics of the arc depend on the power source, wire gauge and insulation type, circuit protection and series resistance rather than type of initiation. The initiation method employed for these tests was applying an oil and graphite mixture to the ends of a powered twisted pair wire. The flight configuration of the heater circuits, the fuel/oxider (or ox) wire, and the RCS jet solenoid were modeled in the test configuration so that the behavior of these components during an arcing event could be studied. To determine if coil activation would occur with various protection wire schemes, 145 tests were conducted using various fuel/ox wire alternatives (shielded and unshielded) and/or different combinations of polytetrafuloroethylene (PTFE), Mystik tape and convoluted wraps to prevent unwanted coil activation. Test results were evaluated along with other pertinent data and information to develop a mitigation strategy for an inadvertent RCS firing. The SSP evaluated civilian aircraft wiring failures to search for aging trends in assessing the wire-short hazard. Appendix 2 applies Weibull statistical methods to the same data with a similar purpose.

Evaluation of pyrolysis and arc tracking on candidate wire insulation designs for space applications

NASA Technical Reports Server (NTRS)

Stueber, Thomas J.; Hrovat, Kenneth

1994-01-01

The ability of wire insulation materials and constructions to resist arc tracking was determined and the damage caused by initial arcing and restrike events was assessed. Results of arc tracking tests on various insulation constructions are presented in view-graph format. Arc tracking tests conducted on Champlain, Filotex, and Teledyne Thermatics indicate the Filotex is least likely to arc track. Arc tracking occurs more readily in air than it does in vacuum.

Effects of Anode Arc Root Fluctuation on Coating Quality During Plasma Spraying

NASA Astrophysics Data System (ADS)

An, Lian-Tong; Gao, Yang; Sun, Chengqi

2011-06-01

To obtain a coating of high quality, a new type of plasma torch was designed and constructed to increase the stability of the plasma arc and reduce the air entrainment into the plasma jet. The torch, called bi-anode torch, generates an elongated arc with comparatively high arc voltage and low arc fluctuation. Spraying experiments were carried out to compare the quality of coatings deposited by a conventional torch and a bi-anode torch. Alumina coatings and tungsten carbide coatings were prepared to appraise the heating of the sprayed particles in the plasma jets and the entrainment of the surrounding air into the plasma jets, respectively. The results show that anode arc root fluctuation has only a small effect on the melting rate of alumina particles. On the other hand, reduced air entrainment into the plasma jet of the bi-anode torch will drastically reduce the decarbonization of tungsten carbide coatings.

Arc spray fabrication of metal matrix composite monotape

NASA Technical Reports Server (NTRS)

Westfall, L. J. (Inventor)

1985-01-01

Arc metal spraying is used to spray liquid metal onto an array of high strength fibers that were previously wound onto a large drum contained inside a controlled atmosphere chamber. This chamber is first evacuated to remove gaseous contaminants and then backfilled with a neutral gas up to atmospheric pressure. This process is used to produce a large size metal matrix composite monotape.

Hexavalent chromium content in stainless steel welding fumes is dependent on the welding process and shield gas type.

PubMed

Keane, Michael; Stone, Samuel; Chen, Bean; Slaven, James; Schwegler-Berry, Diane; Antonini, James

2009-02-01

Occupational exposure to welding fumes is a known health hazard. To isolate elements in stainless steel welding fumes with high potential for adverse health outcomes, fumes were generated using a robotic gas metal arc system, using four shield gases of varying oxygen content. The objective was to measure Cr(VI) concentrations in a broad spectrum of gas metal arc welding processes, and identify processes of exceptionally high or low Cr(VI) content. The gases used were 95% Ar/5% O(2), 98% Ar/2% O(2), 95% Ar/5%CO(2), and 75% He/25% Ar. The welder was operated in axial spray mode (Ar/O(2), Ar/CO(2)), short-circuit (SC) mode (Ar/CO(2) low voltage and He/Ar), and pulsed axial-spray mode (98% Ar/2% O(2)). Results indicate large differences in Cr(VI) in the fumes, with Ar/O(2) (Pulsed)>Ar/O(2)>Ar/CO(2)>Ar/CO(2) (SC)>He/Ar; values were 3000+/-300, 2800+/-85, 2600+/-120, 1400+/-190, and 320+/-290 ppm respectively (means +/- standard errors for 2 runs and 3 replicates per run). Respective rates of Cr(VI) generation were 1.5, 3.2, 4.4, 1.3, and 0.46 microg/min; generation rates were also calculated in terms of microg Cr(VI) per metre of wire used. The generation rates of Cr(VI) increased with increasing O(3) concentrations. Particle size measurements indicated similar distributions, but somewhat higher >0.6 microm fractions for the short-circuit mode samples. Fumes were also sampled into 2 selected size ranges, a microspatter fraction (>or=0.6 microm) and a fine (<0.6 microm) fraction; analysis indicated that Cr(VI) is primarily associated with particles <0.6 microm. The conclusion of the study is that Cr(VI) concentrations vary significantly with welding type and shield gas type, and this presents an opportunity to tailor welding practices to lessen Cr(VI) exposures in workplaces by selecting low Cr(VI)-generating processes. Short-circuit processes generated less Cr(VI) than axial-spray methods, and inert gas shielding gave lower Cr(VI) content than shielding with active gases. A short circuit He/Ar shielded process and a pulsed axial spray Ar/O(2) process were both identified as having substantially lower Cr(VI) generation rates per unit of wire used relative to the other processes studied.

A review of wiring system safety in space power systems

NASA Technical Reports Server (NTRS)

Stavnes, Mark W.; Hammoud, Ahmad N.

1993-01-01

Wiring system failures have resulted from arc propagation in the wiring harnesses of current aerospace vehicles. These failures occur when the insulation becomes conductive upon the initiation of an arc. In some cases, the conductive path of the carbon arc track displays a high enough resistance such that the current is limited, and therefore may be difficult to detect using conventional circuit protection. Often, such wiring failures are not simply the result of insulation failure, but are due to a combination of wiring system factors. Inadequate circuit protection, unforgiving system designs, and careless maintenance procedures can contribute to a wiring system failure. This paper approaches the problem with respect to the overall wiring system, in order to determine what steps can be taken to improve the reliability, maintainability, and safety of space power systems. Power system technologies, system designs, and maintenance procedures which have led to past wiring system failures will be discussed. New technologies, design processes, and management techniques which may lead to improved wiring system safety will be introduced.

Kapton wire arc track testing: Per test procedure KWATT BB01

NASA Technical Reports Server (NTRS)

1990-01-01

The results are presented of Kapton wire arc tracking tests performed at NASA-Johnson in 1990 using test procedure KWATT BB01. The tests were performed to gather data for use in assessing the safety of the Space Shuttle Orbiter wiring which is predominantly Kapton insulated.

Composite-Metal-Matrix Arc-Spray Process

NASA Technical Reports Server (NTRS)

Westfall, Leonard J.

1987-01-01

Arc-spray "monotape" process automated, low in cost, and produces at high rate. Ideal for development of new metal-matrix composites. "Monotape" reproducible and of high quality. Process carried out in controlled gas environment with programmable matrix-deposition rates, resulting in significant cost saving

Wire insulation defect detector

NASA Technical Reports Server (NTRS)

Greulich, Owen R. (Inventor)

2004-01-01

Wiring defects are located by detecting a reflected signal that is developed when an arc occurs through the defect to a nearby ground. The time between the generation of the signal and the return of the reflected signal provides an indication of the distance of the arc (and therefore the defect) from the signal source. To ensure arcing, a signal is repeated at gradually increasing voltages while the wire being tested and a nearby ground are immersed in a conductive medium. In order to ensure that the arcing occurs at an identifiable time, the signal whose reflection is to be detected is always made to reach the highest potential yet seen by the system.

Vision-aided Monitoring and Control of Thermal Spray, Spray Forming, and Welding Processes

NASA Technical Reports Server (NTRS)

Agapakis, John E.; Bolstad, Jon

1993-01-01

Vision is one of the most powerful forms of non-contact sensing for monitoring and control of manufacturing processes. However, processes involving an arc plasma or flame such as welding or thermal spraying pose particularly challenging problems to conventional vision sensing and processing techniques. The arc or plasma is not typically limited to a single spectral region and thus cannot be easily filtered out optically. This paper presents an innovative vision sensing system that uses intense stroboscopic illumination to overpower the arc light and produce a video image that is free of arc light or glare and dedicated image processing and analysis schemes that can enhance the video images or extract features of interest and produce quantitative process measures which can be used for process monitoring and control. Results of two SBIR programs sponsored by NASA and DOE and focusing on the application of this innovative vision sensing and processing technology to thermal spraying and welding process monitoring and control are discussed.

A new test method for the assessment of the arc tracking properties of wire insulation in air, oxygen enriched atmospheres and vacuum

NASA Technical Reports Server (NTRS)

Koenig, Dieter

1994-01-01

Development of a new test method suitable for the assessment of the resistance of aerospace cables to arc tracking for different specific environmental and network conditions of spacecraft is given in view-graph format. The equipment can be easily adapted for tests at different realistic electrical network conditions incorporating circuit protection and the test system works equally well whatever the test atmosphere. Test results confirm that pure Kapton insulated wire has bad arcing characteristics and ETFE insulated wire is considerably better in air. For certain wires, arc tracking effects are increased at higher oxygen concentrations and significantly increased under vacuum. All tests on different cable insulation materials and in different environments, including enriched oxygen atmospheres, resulted in a more or less rapid extinguishing of all high temperature effects at the beginning of the post-test phase. In no case was a self-maintained fire initiated by the arc.

Fire Protection Informational Exchange

DTIC Science & Technology

2016-07-01

0.95 L/min concurrent spray & 274x521 mm pool (66°C) i. Persistent fuels; turbine fuel in spray/pool; lubricant, hydraulic fluid in spray ii...conjugate image plane La Vision sCMOS + Kl long- distance microscope with CF4 objective wire .. " " " " ... in-line hologram image plane La...distance microscope with CF4 objective wire I phase disrurbanc.e (f= 2000 nun) .. " " " " ... in-line hologram image plane La Vision sCNlOS

Wire-Guide Manipulator For Automated Welding

NASA Technical Reports Server (NTRS)

Morris, Tim; White, Kevin; Gordon, Steve; Emerich, Dave; Richardson, Dave; Faulkner, Mike; Stafford, Dave; Mccutcheon, Kim; Neal, Ken; Milly, Pete

1994-01-01

Compact motor drive positions guide for welding filler wire. Drive part of automated wire feeder in partly or fully automated welding system. Drive unit contains three parallel subunits. Rotations of lead screws in three subunits coordinated to obtain desired motions in three degrees of freedom. Suitable for both variable-polarity plasma arc welding and gas/tungsten arc welding.

76 FR 41659 - Airworthiness Directives; The Boeing Company Model 747 Airplanes

Federal Register 2010, 2011, 2012, 2013, 2014

2011-07-15

...), which could result in electrical arcing between the wires and aluminum conduit and consequent fire or... pumps (if installed), which could result in electrical arcing between the wires and aluminum conduit and...

[Arc spectrum diagnostic and heat coupling mechanism analysis of double wire pulsed MIG welding].

PubMed

Liu, Yong-qiang; Li, Huan; Yang, Li-jun; Zheng, Kai; Gao, Ying

2015-01-01

A double wire pulsed MIG welding test system was built in the present paper, in order to analyze the heat-coupling mechanism of double wire pulsed MIG welding, and study are temperature field. Spectroscopic technique was used in diagnostic analysis of the are, plasma radiation was collected by using hollow probe method to obtain the arc plasma optical signal The electron temperature of double wire pulsed MIG welding arc plasma was calculated by using Boltzmann diagram method, the electron temperature distribution was obtained, a comprehensive analysis of the arc was conducted combined with the high speed camera technology and acquisition means of electricity signal. The innovation of this paper is the combination of high-speed camera image information of are and optical signal of arc plasma to analyze the coupling mechanism for dual arc, and a more intuitive analysis for are temperature field was conducted. The test results showed that a push-pull output was achieved and droplet transfer mode was a drop in a pulse in the welding process; Two arcs attracted each other under the action of a magnetic field, and shifted to the center of the arc in welding process, so a new heat center was formed at the geometric center of the double arc, and flowing up phenomenon occurred on the arc; Dual arc electronic temperature showed an inverted V-shaped distribution overall, and at the geometric center of the double arc, the arc electron temperature at 3 mm off the workpiece surface was the highest, which was 16,887.66 K, about 4,900 K higher than the lowest temperature 11,963.63 K.

Welding Wires To Thin Thermocouple Films

NASA Technical Reports Server (NTRS)

Holanda, Raymond; Kim, Walter S.; Danzey, Gerald A.; Pencil, Eric; Wadel, Mary

1993-01-01

Parallel-gap resistance welding yields joints surviving temperatures of about 1,000 degrees C. Much faster than thermocompression bonding. Also exceeds conductive-paste bonding and sputtering thin films through porous flame-sprayed insulation on prewelded lead wires. Introduces no foreign material into thermocouple circuit and does not require careful control of thickness of flame-sprayed material.

Surface Pre-treatment for Thermally Sprayed ZnAl15 Coatings

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Knoch, M. A.

2017-02-01

Pre-treatment of substrates is an important step in thermal spraying. It is widely accepted that mechanical interlocking is the dominant adhesion mechanism for most substrate-coating combinations. To prevent premature failure, minimum coating adhesion strength, surface preparation grades, and roughness parameters are often specified. For corrosion-protection coatings for offshore wind turbines, an adhesion strength ≥ 5 MPa is commonly assumed to ensure adhesion over service lifetime. In order to fulfill this requirement, Rz > 80 µm and a preparation grade of Sa3 are common specifications. In this study, the necessity of these requirements is investigated using the widely used combination of twin-wire arc-sprayed ZnAl15 on S355J2 + N as a test case. By using different blasting media and parameters, the correlation between coating adhesion and roughness parameters is analyzed. The adhesion strength of these systems is measured using a test method allowing measurements on real parts. The results are compared to DIN EN 582:1993, the European equivalent of ASTM-C633. In another series of experiments, the influence of surface pre-treatment grades Sa2.5 and Sa3 is considered. By combining the results of these three sets of experiments, a guideline for surface pre-treatment and adhesion testing on real parts is proposed for the considered system.

Intergranular metal phase increases thermal shock resistance of ceramic coating

NASA Technical Reports Server (NTRS)

Carpenter, H. W.

1966-01-01

Dispersed copper phase increases the thermal shock resistance of a plasma-arc-sprayed coating of zirconia used as a heat barrier on a metal substrate. A small amount of copper is deposited on the granules of the zirconia powder before arc-spraying the resultant powder composite onto the substrate.

Method for gas-metal arc deposition

DOEpatents

Buhrmaster, C.L.; Clark, D.E.; Smartt, H.B.

1990-11-13

Method and apparatus for gas-metal arc deposition of metal, metal alloys, and metal matrix composites are disclosed. The apparatus contains an arc chamber for confining a D.C. electrical arc discharge, the arc chamber containing an outlet orifice in fluid communication with a deposition chamber having a deposition opening in alignment with the orifice for depositing metal droplets on a coatable substrate. Metal wire is passed continuously into the arc chamber in alignment with the orifice. Electric arcing between the metal wire anode and the orifice cathode produces droplets of molten metal from the wire which pass through the orifice and into the deposition chamber for coating a substrate exposed at the deposition opening. When producing metal matrix composites, a suspension of particulates in an inert gas enters the deposition chamber via a plurality of feed openings below and around the orifice so that reinforcing particulates join the metal droplets to produce a uniform mixture which then coats the exposed substrate with a uniform metal matrix composite. 1 fig.

Method for gas-metal arc deposition

DOEpatents

Buhrmaster, Carol L.; Clark, Denis E.; Smartt, Herschel B.

1990-01-01

Method and apparatus for gas-metal arc deposition of metal, metal alloys, and metal matrix composites. The apparatus contains an arc chamber for confining a D.C. electrical arc discharge, the arc chamber containing an outlet orifice in fluid communication with a deposition chamber having a deposition opening in alignment wiht the orifice for depositing metal droplets on a coatable substrate. Metal wire is passed continuously into the arc chamber in alignment with the orifice. Electric arcing between the metal wire anode and the orifice cathode produces droplets of molten metal from the wire which pass through the orifice and into the deposition chamber for coating a substrate exposed at the deposition opening. When producing metal matrix composites, a suspension of particulates in an inert gas enters the deposition chamber via a plurality of feed openings below and around the orifice so that reinforcing particulates join the metal droplets to produce a uniform mixture which then coats the exposed substrate with a uniform metal matrix composite.

Apparatus for gas-metal arc deposition

DOEpatents

Buhrmaster, Carol L.; Clark, Denis E.; Smartt, Herschel B.

1991-01-01

Apparatus for gas-metal arc deposition of metal, metal alloys, and metal matrix composites. The apparatus contains an arc chamber for confining a D.C. electrical arc discharge, the arc chamber containing an outlet orifice in fluid communication with a deposition chamber having a deposition opening in alignment with the orifice for depositing metal droplets on a coatable substrate. Metal wire is passed continuously into the arc chamber in alignment with the orifice. Electric arcing between the metal wire anode and the orifice cathode produces droplets of molten metal from the wire which pass through the orifice and into the deposition chamber for coating a substrate exposed at the deposition opening. When producing metal matrix composites, a suspenion of particulates in an inert gas enters the deposition chamber via a plurality of feed openings below and around the orifice so that reinforcing particulates join the metal droplets to produce a uniform mixture which then coats the exposed substrate with a uniform metal matrix composite.

Pulsed arc plasma jet synchronized with drop-on-demand dispenser

NASA Astrophysics Data System (ADS)

Mavier, F.; Lemesre, L.; Rat, V.; Bienia, M.; Lejeune, M.; Coudert, J.-F.

2017-04-01

This work concerns with the liquid injection in arc plasma spraying for the development of finely structured ceramics coatings. Nanostructured coatings can be now achieved with nanopowders dispersed in a liquid (SPS: Suspension Plasma Spraying) or with a salt dissolved into a liquid (SPPS: Solution Precursor Plasma Spraying) injected into the plasma jet. Controlling electric arc instabilities confined in non-transferred arc plasma torch is therefore a key issue to get reproducible coating properties. Adjustment of parameters with a mono-cathode arc plasma allows a new resonance mode called “Mosquito”. A pulsed arc plasma producing a periodic regular voltage signal with modulation of enthalpy is obtained. The basic idea is to synchronize the injection system with the arc to introduce the liquid material in each plasma oscillation in the same conditions, in order to control the plasma treatment of the material in-fly. A custom-developed pulsed arc plasma torch is used with a drop-on-demand dispenser triggered by the arc voltage. A delay is added to adjust the droplets emission time and their penetration into the plasma gusts. Indeed, the treatment of droplets is also shown to be dependent on this injection delay. A TiO2 suspension and an aqueous solution of aluminium nitrate were optimized to get ejectable inks forming individual droplets. The feasibility of the process was demonstrated for SPS and SPPS techniques. Coatings from the suspension and the solution were achieved. First synchronized sprayings show a good penetration of the droplets into the plasma. Coatings show a fine structure of cauliflowers shapes. The synchronization of the ejection allows a control of morphology and a better deposition efficiency. Further investigations will find the optimal operating parameters to show the full potential of this original liquid injection technique.

WSTF electrical arc projects

NASA Technical Reports Server (NTRS)

Linley, Larry

1994-01-01

The objectives of these projects include the following: validate method used to screen wire insulation with arc tracking characteristics; determine damage resistance to arc as a function of source voltage and insulation thickness; investigate propagation characteristics of Kapton at low voltages; and investigate pyrolytic properties of polyimide insulated (Kapton) wire for low voltage (less than 35 VDC) applications. Supporting diagrams and tables are presented.

[Plasma temperature calculation and coupling mechanism analysis of laser-double wire hybrid welding].

PubMed

Zheng, Kai; Li, Huan; Yang, Li-Jun; Gu, Xiao-Yan; Gao, Ying

2013-04-01

The plasma radiation of laser-double wire hybrid welding was collected by using fiber spectrometer, the coupling mechanism of arc with laser was studied through high-speed photography during welding process, and the temperature of hybrid plasma was calculated by using the method of Boltzmann plot. The results indicated that with laser hybrid, luminance was enhanced; radiation intensity became stronger; arc was attracted to the laser point; cross section contracted and arc was more stable. The laser power, welding current and arc-arc distance are important factors that have great influence on electron temperature. Increase in the laser power, amplification of welding current and reduction of arc-arc distance can all result in the rise of temperature.

Influencing the arc and the mechanical properties of the weld metal in GMA-welding processes by additive elements on the wire electrode surface

NASA Astrophysics Data System (ADS)

Wesling, V.; Schram, A.; Müller, T.; Treutler, K.

2016-03-01

Under the premise of an increasing scarcity of raw materials and increasing demands on construction materials, the mechanical properties of steels and its joints are gaining highly important. In particular high- and highest-strength steels are getting in the focus of the research and the manufacturing industry. To the same extent, the requirements for filler metals are increasing as well. At present, these low-alloy materials are protected by a copper coating (<1μm) against corrosion. In addition, the coating realizes a good ohmic contact and good sliding properties between the welding machine and the wire during the welding process. By exchanging the copper with other elements it should be possible to change the mechanical properties of the weld metal and the arc stability during gas metal arc welding processes and keep the basic functions of the coating nearly untouched. On a laboratory scale solid wire electrodes with coatings of various elements and compounds such as titanium oxide were made and processed with a Gas Metal Arc Welding process. During the processing a different process behavior between the wire electrodes, coated and original, could be observed. The influences ranges from greater/shorter arc-length over increasing/decreasing droplets to larger/smaller arc foot point. Furthermore, the weld metal of the coated electrodes has significantly different mechanical and technological characteristics as the weld metal from the copper coated ground wire. The yield strength and tensile strength can be increased by up to 50%. In addition, the chemical composition of the weld metal was influenced by the application of coatings with layer thicknesses to 15 microns in the lower percentage range (up to about 3%). Another effect of the coating is a modified penetration. The normally occurring “argon finger” can be suppressed or enhanced by the choice of the coating. With the help of the presented studies it will be shown that Gas Metal Arc Welding processes are significantly affected by thin film coatings on solid wire electrodes for Gas Metal Arc welding. The influences are regarding the stability of the arc, the properties of the weld metal in terms of geometric expression, chemical composition and mechanical properties, the composition of the arc-plasma and the dynamics of the molten metal.

Method of producing thermally sprayed metallic coating

DOEpatents

Byrnes, Larry Edward [Rochester Hills, MI; Kramer, Martin Stephen [Clarkston, MI; Neiser, Richard A [Albuquerque, NM

2003-08-26

The cylinder walls of light metal engine blocks are thermally spray coated with a ferrous-based coating using an HVOF device. A ferrous-based wire is fed to the HVOF device to locate a tip end of the wire in a high temperature zone of the device. Jet flows of oxygen and gaseous fuel are fed to the high temperature zone and are combusted to generate heat to melt the tip end. The oxygen is oversupplied in relation to the gaseous fuel. The excess oxygen reacts with and burns a fraction of the ferrous-based feed wire in an exothermic reaction to generate substantial supplemental heat to the HVOF device. The molten/combusted metal is sprayed by the device onto the walls of the cylinder by the jet flow of gases.

Electrical Arc Ignition Testing of Spacesuit Materials

NASA Technical Reports Server (NTRS)

Smith, Sarah; Gallus, Tim; Tapia, Susana; Ball, Elizabeth; Beeson, Harold

2006-01-01

A viewgraph presentation on electrical arc ignition testing of spacesuit materials is shown. The topics include: 1) Background; 2) Test Objectives; 3) Test Sample Materials; 4) Test Methods; 5) Scratch Test Objectives; 6) Cotton Scratch Test Video; 7) Scratch Test Results; 8) Entire Date Plot; 9) Closeup Data Plot; 10) Scratch Test Problems; 11) Poke Test Objectives; 12) Poke Test Results; 13) Poke Test Problems; 14) Wire-break Test Objectives; 15) Cotton Wire-Break Test Video; 16) High Speed Cotton Wire-break Test Video; 17) Typical Data Plot; 18) Closeup Data Plot; 19) Wire-break Test Results; 20) Wire-break Tests vs. Scratch Tests; 21) Urethane-coated Nylon; and 22) Moleskin.

Spray Distribution of Boomless Nozzles: The Boomjet 5880, Radiarc and Boom Buster

Treesearch

James H. Miller

1990-01-01

Abstract. The patterns of spray distribution are described for three boomless nozzlesthat arc commonly used, or have promise, for forestry applications: The BoomJet5880 cluster nozzle (Spraying Systems Co.), the Radiarc (Waldrum specialties ), and the Boom Buster (Evergreen Products). Spray distribution patterns were determined using regularly...

Welding wire pressure sensor assembly

NASA Technical Reports Server (NTRS)

Morris, Timothy B. (Inventor); Milly, Peter F., Sr. (Inventor); White, J. Kevin (Inventor)

1994-01-01

The present invention relates to a device which is used to monitor the position of a filler wire relative to a base material being welded as the filler wire is added to a welding pool. The device is applicable to automated welding systems wherein nonconsumable electrode arc welding processes are utilized in conjunction with a filler wire which is added to a weld pool created by the electrode arc. The invention senses pressure deviations from a predetermined pressure between the filler wire and the base material, and provides electrical signals responsive to the deviations for actuating control mechanisms in an automatic welding apparatus so as to minimize the pressure deviation and to prevent disengagement of the contact between the filler wire and the base material.

[Study on the fluctuation phenomena of arc plasma spraying jet].

PubMed

Zhao, Wen-hua; Liu, Di; Tian, Kuo

2002-08-01

The turbulence phenomenon is one of the most attractive characteristics of a DC arc plasma spraying jet. Most of the previous investigations believe that there is a laminar flow region in core of the jet. A spectrum diagnostic system has been built up in this paper to investigate these effects with the aid of high-speed digital camera. The FFT method has been applied to the analysis on the arc voltage and light signals. The influence of the arc behavior and the power supply on the jet is full-scale. It seems that there is not a laminar flow region in core of the jet. Moreover, from the light dynamic variation graph, the jet fluctuation due to the arc voltage behavior maybe is the dominant characteristic of the jet behavior.

Behaviour of the iron vapour core in the arc of a controlled short-arc GMAW process with different shielding gases

NASA Astrophysics Data System (ADS)

Wilhelm, G.; Kozakov, R.; Gött, G.; Schöpp, H.; Uhrlandt, D.

2012-02-01

The controlled metal transfer process (CMT) is a variation of the gas metal arc welding (GMAW) process which periodically varies wire feeding speed. Using a short-arc burning phase to melt the wire tip before the short circuit, heat input to the workpiece is reduced. Using a steel wire and a steel workpiece, iron vapour is produced in the arc, its maximum concentration lying centrally. The interaction of metal vapour and welding gas considerably impacts the arc profile and, consequently, the heat transfer to the weldpool. Optical emission spectroscopy has been applied to determine the radial profiles of the plasma temperature and iron vapour concentration, as well as their temporal behaviour in the arc period for different mixtures of Ar, O2 and CO2 as shielding gases. Both the absolute iron vapour density and the temporal expansion of the iron core differ considerably for the gases Ar + 8%O2, Ar + 18% CO2 and 100% CO2 respectively. Pronounced minimum in the radial temperature profile is found in the arc centre in gas mixtures with high Ar content under the presence of metal vapour. This minimum disappears in pure CO2 gas. Consequently, the temperature and electrical and thermal conductivity in the arc when CO2 is used as a shielding gas are considerably lower.

Modeling, simulation and control of pulsed DE-GMA welding process for joining of aluminum to steel

NASA Astrophysics Data System (ADS)

Zhang, Gang; Shi, Yu; Li, Jie; Huang, Jiankang; Fan, Ding

2014-09-01

Joining of aluminum to steel has attracted significant attention from the welding research community, automotive and rail transportation industries. Many current welding methods have been developed and applied, however, they can not precisely control the heat input to work-piece, they are high costs, low efficiency and consist lots of complex welding devices, and the generated intermetallic compound layer in weld bead interface is thicker. A novel pulsed double electrode gas metal arc welding(Pulsed DE-GMAW) method is developed. To achieve a stable welding process for joining of aluminum to steel, a mathematical model of coupled arc is established, and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed. Then, the impulse control simulation of coupled arc length, wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece(CTWD). To prove the proposed PSO based PID control scheme's feasibility, the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel. The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length, wire feed speed and the average main arc voltage when the welding process is disturbed, and the developed controller has a faster response and adjustment, only runs about 0.1 s. The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s. The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current. The control experiment proves the accuracy of proposed model and feasibility of new control scheme further. The beautiful and smooth weld beads are also obtained by this method. Pulsed DE-GMAW can thus be considered as an alternative method for low cost, high efficiency joining of aluminum to steel.

Method for controlling gas metal arc welding

DOEpatents

Smartt, Herschel B.; Einerson, Carolyn J.; Watkins, Arthur D.

1989-01-01

The heat input and mass input in a Gas Metal Arc welding process are controlled by a method that comprises calculating appropriate values for weld speed, filler wire feed rate and an expected value for the welding current by algorithmic function means, applying such values for weld speed and filler wire feed rate to the welding process, measuring the welding current, comparing the measured current to the calculated current, using said comparison to calculate corrections for the weld speed and filler wire feed rate, and applying corrections.

Relation Between the Arc-Root Fluctuations, the Cold Boundary Layer Thickness and the Particle Thermal Treatment

NASA Astrophysics Data System (ADS)

Noguès, E.; Fauchais, P.; Vardelle, M.; Granger, P.

2007-12-01

In plasma spraying, the arc-root fluctuations, modifying the length and characteristics of the plasma jet, have an important influence on particle thermal treatment. These voltage fluctuations are strongly linked to the thickness of the cold boundary layer (CBL), surrounding the arc column. This thickness depends on the plasma spray parameters (composition and plasma forming gas mass flow rate, arc current, etc.) and the plasma torch design (anode-nozzle internal diameter and shape, etc.). In order to determine the influence of these different spray parameters on the CBL properties and voltage fluctuations, experiments were performed with two different plasma torches from Sulzer Metco. The first one is a PTF4 torch with a cylindrical anode-nozzle, working with Ar-H2 plasma gas mixtures and the second one is a 3MB torch with either a conical or a cylindrical anode-nozzle, working with N2-H2 plasma gas mixtures. Moreover, arc voltage fluctuations influence on particle thermal treatment was studied through the measurements of transient temperature and velocity of particles, issued from an yttria partially stabilized zirconia powder with a size distribution between 5 and 25 μm.

Study of the spray to globular transition in gas metal arc welding: a spectroscopic investigation

NASA Astrophysics Data System (ADS)

Valensi, F.; Pellerin, S.; Castillon, Q.; Boutaghane, A.; Dzierzega, K.; Zielinska, S.; Pellerin, N.; Briand, F.

2013-06-01

The gas metal arc welding (GMAW) process is strongly influenced by the composition of the shielding gas. In particular, addition of CO2 increases the threshold current for the transition from unstable globular to more stable spray transfer mode. We report on the diagnostics—using optical emission spectroscopy—of a GMAW plasma in pure argon and in mixtures of argon, CO2 and N2 while operated in spray and globular transfer modes. The spatially resolved plasma parameters are obtained by applying the Abel transformation to laterally integrated emission data. The Stark widths of some iron lines are used to determine both electron density and temperature, and line intensities yield relative contents of neutral and ionized iron to argon. Our experimental results indicate a temperature drop on the arc axis in the case of spray arc transfer. This drop reduces with addition of N2 and disappears in globular transfer mode when CO2 is added. Despite the temperature increase, the electron density decreases with CO2 concentration. The highest concentration of iron is observed in the plasma column upper part (close to the anode) and for GMAW with CO2. Our results are compared with recently published works where the effect of non-homogeneous metal vapour concentration has been taken into account.

Electromagnetic characteristic of twin-wire indirect arc welding

NASA Astrophysics Data System (ADS)

Shi, Chuanwei; Zou, Yong; Zou, Zengda; Wu, Dongting

2015-01-01

Traditional welding methods are limited in low heat input to workpiece and high welding wire melting rate. Twin-wire indirect arc(TWIA) welding is a new welding method characterized by high melting rate and low heat input. This method uses two wires: one connected to the negative electrode and another to the positive electrode of a direct-current(DC) power source. The workpiece is an independent, non-connected unit. A three dimensional finite element model of TWIA is devised. Electric and magnetic fields are calculated and their influence upon TWIA behavior and the welding process is discussed. The results show that with a 100 A welding current, the maximum temperature reached is 17 758 K, arc voltage is 14.646 V while maximum current density was 61 A/mm2 with a maximum Lorene force of 84.5 μN. The above mentioned arc parameters near the cathode and anode regions are far higher than those in the arc column region. The Lorene force is the key reason for plasma velocity direction deviated and charged particles flowed in the channel formed by the cathode, anode and upper part of arc column regions. This led to most of the energy being supplied to the polar and upper part of arc column regions. The interaction between electric and magnetic fields is a major determinant in shaping TWIA as well as heat input on the workpiece. This is a first study of electromagnetic characteristics and their influences in the TWIA welding process, and it is significant in both a theoretical and practical sense.

Control of occupational exposure to hexavalent chromium and ozone in tubular wire arc-welding processes by replacement of potassium by lithium or by addition of zinc.

PubMed

Dennis, John H; French, Michael J; Hewitt, Peter J; Mortazavi, Seyed B; Redding, Christopher A J

2002-01-01

Hexavalent chromium [Cr(VI)] and ozone are produced in many arc-welding processes. Cr(VI) is formed when welding with chromium-containing alloys and is a suspected carcinogen. Ozone is formed by the action of ultraviolet light from the arc on oxygen and can cause severe irritation to the eyes and mucous membranes. Previous work has demonstrated that reduction of sodium and potassium in manual metal arc-welding electrodes leads to substantial reductions in Cr(VI) concentrations in the fume as well as a reduction in the fume formation rate. In this paper replacement of potassium by lithium in a tubular wire welding electrode (self-shielding flux-cored) is shown to give reductions in Cr(VI) concentrations and fume formation rates. Previous work has also demonstrated that use of a tubular wire (metal cored) containing 1% zinc can, under certain conditions, result in a reduction in Cr(VI) formation rate and in ozone concentration near the arc but with a rise in the total fume formation rate. The effects of different shield gases and different levels of zinc are examined. An experimental chromium-containing tubular wire with 1% zinc was used with the following shield gases: argon, Argoshield 5, Argoshield 20, Helishield 101, Ar + 2% CO2, Ar + 5% CO2, Ar + 1% O2 and Ar + 2% O2. The wire gave > 98% reduction in Cr(VI) formation rate compared to the control wire provided the shield gas contained no oxygen. When the shield gas did contain oxygen, 1% zinc enhanced Cr(VI) formation rate, resulting in more than double the rates measured when welding with the control wire. Experiments with zinc concentrations, from 0.018 to 0.9% using Helishield 101, gave results indicating that there is an optimum zinc concentration from the point of view of Cr(VI) reduction. Implications of the use of lithium or zinc on the overall exposure risk are discussed.

Electrical Arc Ignition Testing for Constellation Program

NASA Technical Reports Server (NTRS)

Sparks, Kyle; Gallus, Timothy; Smith, Sarah

2009-01-01

NASA Johnson Space Center (JSC) Materials and Processes Branch requested that NASA JSC White Sands Test Facility (WSTF) perform testing for the Constellation Program to evaluate the hazard of electrical arc ignition of materials that could be in close proximity to batteries. Specifically, WSTF was requested to perform wire-break electrical arc tests to determine the current threshold for ignition of generic cotton woven fabric samples with a fixed voltage of 3.7 V, a common voltage for hand-held electrical devices. The wire-break test was developed during a previous test program to evaluate the hazard of electrical arc ignition inside the Extravehicular Mobility Unit [1].

Butt Welding Joint of Aluminum Alloy by Space GHTA Welding Process in Vacuum

NASA Astrophysics Data System (ADS)

Suita, Yoshikazu; Shinike, Shuhei; Ekuni, Tomohide; Terajima, Noboru; Tsukuda, Yoshiyuki; Imagawa, Kichiro

Aluminum alloys have been used widely in constructing various space structures including the International Space Station (ISS) and launch vehicles. For space applications, welding experiments on aluminum alloy were performed using the GHTA (Gas Hollow Tungsten Arc) welding process using a filler wire feeder in a vacuum. We investigated the melting phenomenon of the base metal and filler wire, bead formation, and the effects of wire feed speed on melting characteristics. The melting mechanism in the base metal during the bead on a plate with wire feed was similar to that for the melt run without wire feed. We clarified the effects of wire feed speed on bead sizes and configurations. Furthermore, the butt welded joint welded using the optimum wire feed speed, and the joint tensile strengths were evaluated. The tensile strength of the square butt joint welded by the pulsed DC GHTA welding with wire feed in a vacuum is nearly equal to that of the same joint welded by conventional GTA (Gas Tungsten Arc) welding in air.

Method for controlling gas metal arc welding

DOEpatents

Smartt, H.B.; Einerson, C.J.; Watkins, A.D.

1987-08-10

The heat input and mass input in a Gas Metal Arc welding process are controlled by a method that comprises calculating appropriate values for weld speed, filler wire feed rate and an expected value for the welding current by algorithmic function means, applying such values for weld speed and filler wire feed rate to the welding process, measuring the welding current, comparing the measured current to the calculated current, using said comparison to calculate corrections for the weld speed and filler wire feed rate, and applying corrections. 3 figs., 1 tab.

Effect of epoxy resin sealing on corrosion resistance of arc spraying aluminium coating using cathode electrophoresis method

NASA Astrophysics Data System (ADS)

Pang, Xuming; Wang, Runqiu; Wei, Qian; Zhou, Jianxin

2018-01-01

Arc-sprayed Al coating was sealed with epoxy resin using the cathode electrophoresis method. The anti-corrosion performance of the coatings sealed with epoxy resin was studied by means of a 3.5 wt.% NaCl solution test at 40 °C. For comparison, the anti-corrosion performance of Al coating sealed with boiling water was also performed under the same conditions. The results show that epoxy resin with a thickness of about 20 microns can entirely cover open pores and decreases the surface roughness of the as-sprayed Al coating, and the epoxy resin even permeates into the gaps among lamellar splats from open pores. After corrosion, the thickness of the epoxy resin layer is unchanged and can still cover the as-sprayed Al coating entirely. However, the thickness of Al coating sealed with boiling water decreases from 100 to 40 microns, which indicates that the arc-sprayed Al coating has much better corrosion resistance than the Al coating sealed with boiling water. Meanwhile, the content of substituted benzene ring in the epoxy resin increases, but aromatic ring decreases according to the fourier transform infrared spectra, which will cause the rigidity of the epoxy resin to increase, but the toughness slightly decreases after corrosion.

Technique for the comparison of light spectra from natural and laboratory generated lightning current arcs

NASA Astrophysics Data System (ADS)

Mitchard, D.; Clark, D.; Carr, D.; Haddad, A.

2016-08-01

A technique was developed for the comparison of observed emission spectra from lightning current arcs generated through self-breakdown in air and the use of two types of initiation wire, aluminum bronze and nichrome, against previously published spectra of natural lightning events. A spectrograph system was used in which the wavelength of light emitted by the lightning arc was analyzed to derive elemental interactions. A lightning impulse of up to 100 kA was applied to a two hemispherical tungsten electrode configuration which allowed the effect of the lightning current and lightning arc length to be investigated. A natural lightning reference spectrum was reconstructed from literature, and generated lightning spectra were obtained from self-breakdown across a 14.0 mm air gap and triggered along initiation wires of length up to 72.4 mm. A comparison of the spectra showed that the generated lightning arc induced via self-breakdown produced a very similar spectrum to that of natural lightning, with the addition of only a few lines from the tungsten electrodes. A comparison of the results from the aluminum bronze initiation wire showed several more lines, whereas results from the nichrome initiation wire differed greatly across large parts of the spectrum. This work highlights the potential use for spectrographic techniques in the study of lightning interactions with surrounding media and materials, and in natural phenomena such as recently observed ball lightning.

Sprayed shielding of plastic-encapsulated electronic modules

NASA Technical Reports Server (NTRS)

Muller, A. N.

1969-01-01

Metallic coating directly sprayed on electronic modules provides simple and reliable lightweight protection against radio frequency interference. A plasma arc may be used. Aluminum and copper are the most effective metals.

Sol-gel-Derived nano-sized double layer anti-reflection coatings (SiO2/TiO2) for low-cost solar cell fabrication.

PubMed

Lee, Seung Jun; Hur, Man Gyu; Yoon, Dae Ho

2013-11-01

We investigate nano-sized double layer anti-reflection coatings (ARCs) using a TiO2 and SiO2 sol-gel solution process for mono-crystalline silicon solar cells. The process can be easily adapted for spraying sol-gel coatings to reduce manufacturing cost. The spray-coated SiO2/TiO2 nano-sized double layer ARCs were deposited on mono-crystalline silicon solar cells, and they showed good optical properties. The spray coating process is a lower-cost fabrication process for large-scale coating than vacuum deposition processes such as PECVD. The measured average optical reflectance (300-1200 nm) was about approximately 8% for SiO2/TiO2 nano-sized double layer ARCs. The electrical parameters of a mono-crystalline silicon solar cell and reflection losses show that the SiO2/TiO2 stacks can improve cell efficiency by 0.2% compared to a non-coated mono-crystalline silicon solar cell. In the results, good correlation between theoretical and experimental data was obtained. We expect that the sol-gel spray-coated mono-crystalline silicon solar cells have high potential for low-cost solar cell fabrication.

MSFC inspections of installed polyimide wire

NASA Technical Reports Server (NTRS)

Landers, Joe C.

1994-01-01

An alert was issued because of the arc-tracking possibilities of installed polyimide wire harnesses. MSFC undertook a program to try to enhance the safety and reliability of these harnesses. Photographs are presented showing the need for inspections of installed wiring harnesses.

Effects of arc current on the life in burner rig thermal cycling of plasma sprayed ZrOsub2-Ysub2Osub3

NASA Technical Reports Server (NTRS)

Hendricks, R. C.; Mcdonald, G.

1982-01-01

An analysis of thermal cycle life data for four sets of eight thermal barrier coated specimens representing arc currents (plasma gun power) of 525, 600, 800, or 950 amps is presented. The ZrO2-8Y2O3/NiCrAlY plasma spray coated Rene 41 rods were thermal cycled to 1040 C in a Mach 0.3-Jet A/air burner flame. The experimental results indicate the existance of a minimum or threshold power level which coating life expectancy is less than 500 cycles. Above the threshold power level, coating life expectancy more than doubles and increases with arc current.

Effects of arc current on the life in burner rig thermal cycling of plasma sprayed ZrOsub2-Ysub2Osub3

NASA Astrophysics Data System (ADS)

Hendricks, R. C.; McDonald, G.

1982-02-01

An analysis of thermal cycle life data for four sets of eight thermal barrier coated specimens representing arc currents (plasma gun power) of 525, 600, 800, or 950 amps is presented. The ZrO2-8Y2O3/NiCrAlY plasma spray coated Rene 41 rods were thermal cycled to 1040 C in a Mach 0.3-Jet A/air burner flame. The experimental results indicate the existance of a minimum or threshold power level which coating life expectancy is less than 500 cycles. Above the threshold power level, coating life expectancy more than doubles and increases with arc current.

Technique for the comparison of light spectra from natural and laboratory generated lightning current arcs

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mitchard, D., E-mail: mitcharddr@cardiff.ac.uk; Clark, D.; Carr, D.

A technique was developed for the comparison of observed emission spectra from lightning current arcs generated through self-breakdown in air and the use of two types of initiation wire, aluminum bronze and nichrome, against previously published spectra of natural lightning events. A spectrograph system was used in which the wavelength of light emitted by the lightning arc was analyzed to derive elemental interactions. A lightning impulse of up to 100 kA was applied to a two hemispherical tungsten electrode configuration which allowed the effect of the lightning current and lightning arc length to be investigated. A natural lightning reference spectrum wasmore » reconstructed from literature, and generated lightning spectra were obtained from self-breakdown across a 14.0 mm air gap and triggered along initiation wires of length up to 72.4 mm. A comparison of the spectra showed that the generated lightning arc induced via self-breakdown produced a very similar spectrum to that of natural lightning, with the addition of only a few lines from the tungsten electrodes. A comparison of the results from the aluminum bronze initiation wire showed several more lines, whereas results from the nichrome initiation wire differed greatly across large parts of the spectrum. This work highlights the potential use for spectrographic techniques in the study of lightning interactions with surrounding media and materials, and in natural phenomena such as recently observed ball lightning.« less

Electrode carrying wire for GTAW welding

NASA Technical Reports Server (NTRS)

Morgan, Gene E. (Inventor); Dyer, Gerald E. (Inventor)

1990-01-01

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.

Internal wire guide for GTAW welding

NASA Technical Reports Server (NTRS)

Morgan, Gene E. (Inventor); Dyer, Gerald E. (Inventor)

1989-01-01

A welding torch for gas tungsten arc welding apparatus has a filler metal wire guide positioned within the torch, and within the shielding gas nozzle. The wire guide is adjacent to the tungsten electrode and has a ceramic liner through which the wire is fed. This reduces the size of the torch and eliminates the outside clearance problems that exit with external wire guides. Additionally, since the wire is always within the shielding gas, oxidizing of the wire is eliminated.

Controlling Arc Length in Plasma Welding

NASA Technical Reports Server (NTRS)

Iceland, W. F.

1986-01-01

Circuit maintains arc length on irregularly shaped workpieces. Length of plasma arc continuously adjusted by control circuit to maintain commanded value. After pilot arc is established, contactor closed and transfers arc to workpiece. Control circuit then half-wave rectifies ac arc voltage to produce dc control signal proportional to arc length. Circuit added to plasma arc welding machines with few wiring changes. Welds made with circuit cleaner and require less rework than welds made without it. Beads smooth and free of inclusions.

Research on Mechanisms and Controlling Methods of Macro Defects in TC4 Alloy Fabricated by Wire Additive Manufacturing.

PubMed

Ji, Lei; Lu, Jiping; Tang, Shuiyuan; Wu, Qianru; Wang, Jiachen; Ma, Shuyuan; Fan, Hongli; Liu, Changmeng

2018-06-28

Wire feeding additive manufacturing (WFAM) has broad application prospects because of its advantages of low cost and high efficiency. However, with the mode of lateral wire feeding, including wire and laser additive manufacturing, gas tungsten arc additive manufacturing etc., it is easy to generate macro defects on the surface of the components because of the anisotropy of melted wire, which limits the promotion and application of WFAM. In this work, gas tungsten arc additive manufacturing with lateral wire feeding is proposed to investigate the mechanisms of macro defects. The results illustrate that the defect forms mainly include side spatters, collapse, poor flatness, and unmelted wire. It was found that the heat input, layer thickness, tool path, and wire curvature can have an impact on the macro defects. Side spatters are the most serious defects, mainly because the droplets cannot be transferred to the center of the molten pool in the lateral wire feeding mode. This research indicates that the macro defects can be controlled by optimizing the process parameters. Finally, block parts without macro defects were fabricated, which is meaningful for the further application of WFAM.

Effects of thermal and electrical stressing on the breakdown behavior of space wiring

NASA Technical Reports Server (NTRS)

Hammoud, Ahmad; Stavnes, Mark; Suthar, Jayant; Laghari, Javaid

1995-01-01

Several failures in the electrical wiring systems of many aircraft and space vehicles have been attributed to arc tracking and damaged insulation. In some instances, these failures proved to be very costly as they have led to the loss of many aircraft and imperilment of space missions. Efforts are currently underway to develop lightweight, reliable, and arc track resistant wiring for aerospace applications. In this work, six wiring constructions were evaluated in terms of their breakdown behavior as a function of temperature. These hybrid constructions employed insulation consisting of Kapton, Teflon, and cross-linked Tefzel. The properties investigated included the 400 Hz AC dielectric strength at ambient and 200 C, and the lifetime at high temperature with an applied bias of 40, 60, and 80% of breakdown voltage level. The results obtained are discussed, and conclusions are made concerning the suitability of the wiring constructions investigated for aerospace applications.

Effects of thermal and electrical stressing on the breakdown behavior of space wiring

NASA Astrophysics Data System (ADS)

Hammoud, Ahmad; Stavnes, Mark; Suthar, Jayant; Laghari, Javaid

1995-06-01

Several failures in the electrical wiring systems of many aircraft and space vehicles have been attributed to arc tracking and damaged insulation. In some instances, these failures proved to be very costly as they have led to the loss of many aircraft and imperilment of space missions. Efforts are currently underway to develop lightweight, reliable, and arc track resistant wiring for aerospace applications. In this work, six wiring constructions were evaluated in terms of their breakdown behavior as a function of temperature. These hybrid constructions employed insulation consisting of Kapton, Teflon, and cross-linked Tefzel. The properties investigated included the 400 Hz AC dielectric strength at ambient and 200 C, and the lifetime at high temperature with an applied bias of 40, 60, and 80% of breakdown voltage level. The results obtained are discussed, and conclusions are made concerning the suitability of the wiring constructions investigated for aerospace applications.

Effects of plasma spray parameters on two layer thermal barrier

NASA Technical Reports Server (NTRS)

Stecura, S.

1981-01-01

The power level and the type of arc gas used during plasma spraying of a two layer thermal barrier system (TBS) were found to affect the life of the system. Life at 1095 C in a cyclic furnace test was improved by about 140 percent by increasing the power during plasma spray applications of the bond and thermal barrier coatings. This improvement is due to increases in the densities of the bond and thermal barrier coatings by 3 and 5 percent, respectively. These increases in densities are equivalent to about 45 and 30 percent reduction in mean porosities, respectively. The addition of hydrogen to the argon arc gas had the same effect as the reduction in power level and caused a reduction in TBS life.

Wiring for aerospace applications

NASA Astrophysics Data System (ADS)

Christian, J. L., Jr.; Dickman, J. E.; Bercaw, R. W.; Myers, I. T.; Hammoud, A. N.; Stavnes, M.; Evans, J.

1992-07-01

In this paper, the authors summarize the current state of knowledge of arc propagation in aerospace power wiring and efforts by the National Aeronautics and Space Administration (NASA) towards the understanding of the arc tracking phenomena in space environments. Recommendations will be made for additional testing. A database of the performance of commonly used insulating materials will be developed to support the design of advanced high power missions, such as Space Station Freedom and Lunar/Mars Exploration.

Wiring for aerospace applications

NASA Technical Reports Server (NTRS)

Christian, J. L., Jr.; Dickman, J. E.; Bercaw, R. W.; Myers, I. T.; Hammoud, A. N.; Stavnes, M.; Evans, J.

1992-01-01

In this paper, the authors summarize the current state of knowledge of arc propagation in aerospace power wiring and efforts by the National Aeronautics and Space Administration (NASA) towards the understanding of the arc tracking phenomena in space environments. Recommendations will be made for additional testing. A database of the performance of commonly used insulating materials will be developed to support the design of advanced high power missions, such as Space Station Freedom and Lunar/Mars Exploration.

Surface preparation effects on GTA weld shape in JBK-75 stainless steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Campbell, R.D.; Robertson, A.M.; Heiple, C.R.

1993-02-01

The results of a study are reported here on the effects of surface preparation on the shape of autogenous gas tungsten arc (GTA) welds in JBK-75, an austenitic precipitation hardenable stainless steel similar to A286. Minor changes in surface preparation produced substantial changes in the fusion zone shape and welding behavior of this alloy. Increased and more consistent depth of fusion (higher d/w ratios) along with improved arc stability and less arc wander resulted from wire brushing and other abrasive surface preparations, although chemical and machining methods did not produce any increase in depth of fusion. Abrasive treatments roughen themore » surface, increase the surface area, increase the surface oxide thickness, and entrap oxide. The increased weld d/w ratio is attributed to oxygen added to the weld pool from the surface oxide on the base metal. The added oxygen alters the surface-tension-driven fluid flow pattern in the weld pool. Increased depth of fusion in wire-fed U-groove weld joints also resulted when welding wire with a greater surface oxide thickness was used. Increasing the amount of wire brushing produced even deeper welds. However, a maximum in depth of fusion was observed with further wire brushing, beyond which weld fusion depth decreased.« less

Correlation between fabrication factor and superconducting properties of the Tl-and-Bi-based high-Tc superconductor

NASA Technical Reports Server (NTRS)

Maki, Naoki; Okada, Michiya; Doi, Toshiya J.; Kanai, Tsuneyuki; Sato, Junichi; Higashiyama, Kazutoshi

1995-01-01

Large critical current densities (J(sub c)) were obtained in c axis oriented Tl-1 223/Ag composite tapes fabricated by spraying methods without a vacuum. Transport measurements at 77K under a zero field indicated a J(sub c) of 9 x 10(exp 4) A/sq cm and 7 x 10(exp 3) A/sq cm at 1T for the tapes fabricated by spray pyrolysis. The novel GPM method was also applied for Bi-2212/Ag PIT composite wire, and found to be very effective for improving the distribution of voids, which caused from the melt-solidifying process. The GPM showed a marked effect for obtaining homogeneous long wire. A 1 T class coil was successfully fabricated with monocore wire.

Control of Gas Tungsten Arc welding pool shape by trace element addition to the weld pool

DOEpatents

Heiple, C.R.; Burgardt, P.

1984-03-13

An improved process for Gas Tungsten Arc welding maximizes the depth/width ratio of the weld pool by adding a sufficient amount of a surface active element to insure inward fluid flow, resulting in deep, narrow welds. The process is especially useful to eliminate variable weld penetration and shape in GTA welding of steels and stainless steels, particularly by using a sulfur-doped weld wire in a cold wire feed technique.

Experimental Study on the Electrochemical Anti-Corrosion Properties of Steel Structures Applying the Arc Thermal Metal Spraying Method

PubMed Central

Choe, Hong-Bok; Lee, Han-Seung; Shin, Jun-Ho

2014-01-01

The arc thermal metal spraying method (ATMSM) provides proven long-term protective coating systems using zinc, aluminum and their alloys for steel work in a marine environment. This paper focuses on studying experimentally the anti-corrosion criteria of ATMSM on steel specimens. The effects of the types of spraying metal and the presence or absence of sealing treatment from the thermal spraying of film on the anti-corrosion performance of TMSM were quantitatively evaluated by electrochemical techniques. The results showed that ATMSM represented a sufficient corrosion resistance with the driving force based on the potential difference of more than approximately 0.60 V between the thermal spraying layer and the base substrate steel. Furthermore, it was found that the sealing treatment of specimens had suppressed the dissolution of metals, increased the corrosion potential, decreased the corrosion current density and increased the polarization resistance. Metal alloy Al–Mg (95%:5%) by mass with epoxy sealing coating led to the most successful anti-corrosion performance in these electrochemical experiments. PMID:28788271

Process-based quality for thermal spray via feedback control

NASA Astrophysics Data System (ADS)

Dykhuizen, R. C.; Neiser, R. A.

2006-09-01

Quality control of a thermal spray system manufacturing process is difficult due to the many input variables that need to be controlled. Great care must be taken to ensure that the process remains constant to obtain a consistent quality of the parts. Control is greatly complicated by the fact that measurement of particle velocities and temperatures is a noisy stochastic process. This article illustrates the application of quality control concepts to a wire flame spray process. A central feature of the real-time control system is an automatic feedback control scheme that provides fine adjustments to ensure that uncontrolled variations are accommodated. It is shown how the control vectors can be constructed from simple process maps to independently control particle velocity and temperature. This control scheme is shown to perform well in a real production environment. We also demonstrate that slight variations in the feed wire curvature can greatly influence the process. Finally, the geometry of the spray system and sensor must remain constant for the best reproducibility.

An Obstacle Alerting System for Agricultural Application

NASA Technical Reports Server (NTRS)

DeMaio, Joe

2003-01-01

Wire strikes are a significant cause of helicopter accidents. The aircraft most at risk are aerial applicators. The present study examines the effectiveness of a wire alert delivered by way of the lightbar, a GPS-based guidance system for aerial application. The alert lead-time needed to avoid an invisible wire is compared with that to avoid a visible wire. A flight simulator was configured to simulate an agricultural application helicopter. Two pilots flew simulated spray runs in fields with visible wires, invisible wires, and no wires. The wire alert was effective in reducing wire strikes. A lead-time of 3.5 sec was required for the alert to be effective. The lead- time required was the same whether the pilot could see the wire or not.

Replacing thermal sprayed zinc anodes on cathodically protected steel reinforced concrete bridges.

DOT National Transportation Integrated Search

2011-09-01

This research aimed to address questions underlying the replacement of arc-sprayed zinc anodes on cathodically protected steel reinforced concrete bridges and to develop a protocol to prepare the concrete surface for the new anode, through a combinat...

Replacing thermal sprayed zinc anodes on cathodically protected steel reinforced concrete bridges.

DOT National Transportation Integrated Search

2011-08-01

"This research aimed to address questions underlying the replacement of arc-sprayed zinc anodes on cathodically protected steel reinforced concrete bridges and to develop a protocol to prepare the concrete surface for the new anode, through a combina...

Passenger Transmitters as A Possible Cause of Aircraft Fuel Ignition

NASA Technical Reports Server (NTRS)

Nguyen, Truong X.; Ely, Jay J.; Dudley, Kenneth L.; Scearce, Stephen A.; Hatfield, Michael O.; Richardson, Robert E.

2006-01-01

An investigation was performed to study the potential for radio frequency (RF) power radiated from transmitting Portable Electronic Devices (PEDs) to create an arcing/sparking event within the fuel tank of a large transport aircraft. A survey of RF emissions from typical intentional transmitting PEDs was first performed. Aircraft measurements of RF coupling to the fuel tank and its wiring were also performed to determine the PEDs induced power on the wiring, and the re-radiated power within the fuel tank. Laboratory simulations were conducted to determine the required RF power level for an arcing/sparking event. Data analysis shows large positive safety margins, even with simulated faults on the wiring.

Third NASA Workshop on Wiring for Space Applications

NASA Technical Reports Server (NTRS)

Hammoud, Ahmad (Compiler); Stavnes, Mark (Compiler)

1995-01-01

This workshop addressed key technology issues in the field of electrical power wiring for space applications, and transferred information and technology related to space wiring for use in government and commercial applications. Speakers from space agencies, U.S. Federal labs, industry, and academia presented program overviews and discussed topics on arc tracking phenomena, advancements in insulation materials and constructions, and new wiring system topologies.

Process Simulation of Gas Metal Arc Welding Software

DOE Office of Scientific and Technical Information (OSTI.GOV)

Murray, Paul E.

2005-09-06

ARCWELDER is a Windows-based application that simulates gas metal arc welding (GMAW) of steel and aluminum. The software simulates the welding process in an accurate and efficient manner, provides menu items for process parameter selection, and includes a graphical user interface with the option to animate the process. The user enters the base and electrode material, open circuit voltage, wire diameter, wire feed speed, welding speed, and standoff distance. The program computes the size and shape of a square-groove or V-groove weld in the flat position. The program also computes the current, arc voltage, arc length, electrode extension, transfer ofmore » droplets, heat input, filler metal deposition, base metal dilution, and centerline cooling rate, in English or SI units. The simulation may be used to select welding parameters that lead to desired operation conditions.« less

Enhancement of Combustion and Flame Stabilization Using Transient Non-Equilibrium Plasma

DTIC Science & Technology

2007-03-31

cathode spot D = diameter of MGA device D= diffusivity of i’h species d = diameter of arc dcoected= diametrically corrected diameter of arc d.rwwd... cathode and anode, stabilization (4) respectively (Fig. 1). A wire was attached to the cathode , which was separated from the outer anode by 2 mm at the...smallest gap (point (1) in Fig. 1). The wire spiraled progressively closer to the cathode , where it was attached at the largest gap between the two

Operational environments for electrical power wiring on NASA space systems

NASA Technical Reports Server (NTRS)

Stavnes, Mark W.; Hammoud, Ahmad N.; Bercaw, Robert W.

1994-01-01

Electrical wiring systems are used extensively on NASA space systems for power management and distribution, control and command, and data transmission. The reliability of these systems when exposed to the harsh environments of space is very critical to mission success and crew safety. Failures have been reported both on the ground and in flight due to arc tracking in the wiring harnesses, made possible by insulation degradation. This report was written as part of a NASA Office of Safety and Mission Assurance (Code Q) program to identify and characterize wiring systems in terms of their potential use in aerospace vehicles. The goal of the program is to provide the information and guidance needed to develop and qualify reliable, safe, lightweight wiring systems, which are resistant to arc tracking and suitable for use in space power applications. This report identifies the environments in which NASA spacecraft will operate, and determines the specific NASA testing requirements. A summary of related test programs is also given in this report. This data will be valuable to spacecraft designers in determining the best wiring constructions for the various NASA applications.

Improved microstructure and mechanical properties in gas tungsten arc welded aluminum joints by using graphene nanosheets/aluminum composite filler wires.

PubMed

Fattahi, M; Gholami, A R; Eynalvandpour, A; Ahmadi, E; Fattahi, Y; Akhavan, S

2014-09-01

In the present study, different amounts of graphene nanosheets (GNSs) were added to the 4043 aluminum alloy powders by using the mechanical alloying method to produce the composite filler wires. With each of the produced composite filler wires, one all-weld metal coupon was welded using the gas tungsten arc (GTA) welding process. The microstructure, mechanical properties and fracture surface morphology of the weld metals have been evaluated and the results are compared. As the amount of GNSs in the composition of filler wire is increased, the microstructure of weld metal was changed from the dendritic structure to fine equiaxed grains. Furthermore, the tensile strength and microhardness of weld metal was improved, and is attributed to the augmented nucleation and retarded growth. From the results, it was seen that the GNSs/Al composite filler wire can be used to improve the microstructure and mechanical properties of GTA weld metals of aluminum and its alloys. Copyright © 2014 Elsevier Ltd. All rights reserved.

Wiring test program insulation material related properties

NASA Technical Reports Server (NTRS)

Reher, Heinz-Josef

1995-01-01

This viewgraph presentation provides an overview of activities at DASA-RI concerning the testing of wires for manned spacecraft, including test facilities, arc-tracking tests, flammability tests, microgravity tests, and standardization, and outlines future activities.

Development of strain gages for use to 1311 K (1900 F)

NASA Technical Reports Server (NTRS)

Lemcoe, M. M.

1974-01-01

A high temperature electric resistance strain gage system was developed and evaluated to 1366 K (2000 F) for periods of at least one hour. Wire fabricated from a special high temperature strain gage alloy (BCL-3), was used to fabricate the gages. Various joining techniques (NASA butt welding, pulse arc, plasma needle arc, and dc parallel gap welding) were investigated for joining gage filaments to each other, gage filaments to lead-tab ribbons, and lead-tab ribbons to lead wires. The effectiveness of a clad-wire concept as a means of minimizing apparent strain of BCL-3 strain gages was investigated by sputtering platinum coatings of varying thicknesses on wire samples and establishing the optimum coating thickness--in terms of minimum resistivity changes with temperature. Finally, the moisture-proofing effectiveness of barrier coatings subjected to elevated temperatures was studied, and one commercial barrier coating (BLH Barrier H Waterproofing) was evaluated.

NASA wiring for space applications program test results

NASA Astrophysics Data System (ADS)

Stavnes, Mark; Hammoud, Ahmad

1995-11-01

The electrical power wiring tests results from the NASA Wiring for Space Applications program are presented. The goal of the program was to develop a base for the building of a lightweight, arc track-resistant electrical wiring system for aerospace applications. This new wiring system would be applied to such structures as pressurized modules, trans-atmospheric vehicles, LEO/GEO environments, and lunar and Martian environments. Technological developments from this program include the fabrication of new insulating materials, the production of new wiring constructions, an improved system design, and an advanced circuit protection design.

Three-wire Thermocouple: Frequency Response in Constant Flow

NASA Technical Reports Server (NTRS)

Forney, L. J.; Fralick, G. C.

1995-01-01

Theory and experimental measurements are compared with a novel three-wire thermocouple. Signals from three wires of unequal diameters arc recorded from the thermocouple suspended in constant flow with a periodic temperature fluctuation. It is demonstrated that the reconstructed signal from the three-wire thermocouple requires no compensation for omega less than or equal to 5(sub omega1), where omega, is the natural frequency of the smaller wire. The latter result represents a significant improvement compared to previous work with two-wire thermocouples. A correction factor has also been derived to account for wires of arbitrary diameter.

Process for HIP canning of composites

NASA Technical Reports Server (NTRS)

Juhas, John J. (Inventor)

1990-01-01

A single step is relied on in the canning process for hot isostatic pressing (HIP) metallurgy composites. The composites are made from arc sprayed and plasma sprayed monotape. The HIP can is of compatible refractory metal and is sealed at high vacuum and temperature. This eliminates outgassing during hot isostatic pressing.

Fast, Nonspattering Inert-Gas Welding

NASA Technical Reports Server (NTRS)

Gilbert, Jeffrey L.

1991-01-01

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.

GENERATION AND SIMULATION OF METALLIC PARTICULATE AIR POLLUTANTS BY ELECTRIC ARC SPRAYING

EPA Science Inventory

The report gives results of efforts to provide a generated output with an appropriate mass and concentration of fresh, dry, fine metal oxide particles for bench or pilot scale fine particulate collection research and development work. The work involved two electric arc aerosol ge...

Fabrication of Copper-Rich Cu-Al Alloy Using the Wire-Arc Additive Manufacturing Process

NASA Astrophysics Data System (ADS)

Dong, Bosheng; Pan, Zengxi; Shen, Chen; Ma, Yan; Li, Huijun

2017-12-01

An innovative wire-arc additive manufacturing (WAAM) process is used to fabricate Cu-9 at. pct Al on pure copper plates in situ, through separate feeding of pure Cu and Al wires into a molten pool, which is generated by the gas tungsten arc welding (GTAW) process. After overcoming several processing problems, such as opening the deposition molten pool on the extremely high-thermal conductive copper plate and conducting the Al wire into the molten pool with low feed speed, the copper-rich Cu-Al alloy was successfully produced with constant predesigned Al content above the dilution-affected area. Also, in order to homogenize the as-fabricated material and improve the mechanical properties, two further homogenization heat treatments at 1073 K (800 °C) and 1173 K (900 °C) were applied. The material and mechanical properties of as-fabricated and heat-treated samples were compared and analyzed in detail. With increased annealing temperatures, the content of precipitate phases decreased and the samples showed gradual improvements in both strength and ductility with little variation in microstructures. The present research opened a gate for in-situ fabrication of Cu-Al alloy with target chemical composition and full density using the additive manufacturing process.

Longitudinal magnet forces?

NASA Astrophysics Data System (ADS)

Graneau, P.

1984-03-01

The Ampere electrodynamics of metallic conductors and experiments supporting it predict that the interaction of a current-carrying wire with its own magnetic field should produce longitudinal mechanical forces in the conductor, existing in addition to the transverse Lorentz forces. The longitudinal forces should stretch the conductor and have been referred to as Ampere tension. In 1964 it was discovered that a current pulse would break a straight copper wire into many fragments without visible melting. A metallurgical examination of the pieces confirmed that the metal parted in the solid state. The same observation has now been made with aluminum wires. In the latest experiments the wire was bent into a semicircle and arc-connected to a capacitor discharge circuit. The arc connections ruled out rupture by Lorentz hoop tension and indicated the longitudinal forces may also arise in circular magnet windings. Explanations of wire fragmentation by thermal shock, longitudinal stress waves, Lorentz pinch-off, bending stresses, and material defects have been considered and found unconvincing. Computed Ampere tensions would be sufficient to fracture hot wires. The Ampere tension would double the hoop tension normally expected in dipole magnets. This should be borne in mind in the design of large dipole magnets contemplated for MHD power generators and railgun accelerators.

Numerical investigations of arc behaviour in gas metal arc welding using ANSYS CFX

NASA Astrophysics Data System (ADS)

Schnick, M.; Fuessel, U.; Hertel, M.; Spille-Kohoff, A.; Murphy, A. B.

2011-06-01

Current numerical models of gas metal arc welding (GMAW) are trying to combine magnetohydrodynamics (MHD) models of the arc and volume of fluid (VoF) models of metal transfer. They neglect vaporization and assume an argon atmosphere for the arc region, as it is common practice for models of gas tungsten arc welding. These models predict temperatures above 20 000 K and a temperature distribution similar to tungsten inert gas (TIG) arcs. However, current spectroscopic temperature measurements in GMAW arcs demonstrate much lower arc temperatures. In contrast to TIG arcs they found a central local minimum of the radial temperature distribution. The paper presents a GMAW arc model that considers metal vapour and which is in a very good agreement with experimentally observed temperatures. Furthermore, the model is able to predict the local central minimum in the radial temperature and the radial electric current density distributions for the first time. The axially symmetric model of the welding torch, the work piece, the wire and the arc (fluid domain) implements MHD as well as turbulent mixing and thermal demixing of metal vapour in argon. The mass fraction of iron vapour obtained from the simulation shows an accumulation in the arc core and another accumulation on the fringes of the arc at 2000 to 5000 K. The demixing effects lead to very low concentrations of iron between these two regions. Sensitive analyses demonstrate the influence of the transport and radiation properties of metal vapour, and the evaporation rate relative to the wire feed. Finally the model predictions are compared with the measuring results of Zielińska et al.

Surface preparation effects on GTA (gas tungsten arc) weld penetration in JBK-75 stainless steel

DOE Office of Scientific and Technical Information (OSTI.GOV)

Campbell, R.D.; Heiple, C.R.; Sturgill, P.L.

1989-01-01

The results of a study are reported here on the effects of surface preparation on the shape of GTA welds on JBK-75, an austenitic precipitation hardenable stainless steel similar to A286. Minor changes in surface (weld groove) preparation produced substantial changes in the penetration characteristics and welding behavior of this alloy. Increased and more consistent weld penetration (higher d/w ratios) along with improved arc stability and less arc wander result from wire brushing and other abrasive surface preparations, although chemical and machining methods did not produce any improvement in penetration. Abrasive treatments roughen the surface, increase the surface area, andmore » increase the surface oxide thickness. The increased weld d/w ratio is attributed to oxygen added to the weld pool from the surface oxide on the base metal. The added oxygen alters the surface-tension driven fluid flow pattern in the weld pool. Similar results were observed with changes in filler wire surface oxide thickness, caused by changes in wire production conditions. 15 refs., 14 figs., 4 tabs.« less

Process stability during fiber laser-arc hybrid welding of thick steel plates

NASA Astrophysics Data System (ADS)

Bunaziv, Ivan; Frostevarg, Jan; Akselsen, Odd M.; Kaplan, Alexander F. H.

2018-03-01

Thick steel plates are frequently used in shipbuilding, pipelines and other related heavy industries, and are usually joined by arc welding. Deep penetration laser-arc hybrid welding could increase productivity but has not been thoroughly investigated, and is therefore usually limited to applications with medium thickness (5-15 mm) sections. A major concern is process stability, especially when using modern welding consumables such as metal-cored wire and advanced welding equipment. High speed imaging allows direct observation of the process so that process behavior and phenomena can be studied. In this paper, 45 mm thick high strength steel was welded (butt joint double-sided) using the fiber laser-MAG hybrid process utilizing a metal-cored wire without pre-heating. Process stability was monitored under a wide range of welding parameters. It was found that the technique can be used successfully to weld thick sections with appropriate quality when the parameters are optimized. When comparing conventional pulsed and the more advanced cold metal transfer pulse (CMT+P) arc modes, it was found that both can provide high quality welds. CMT+P arc mode can provide more stable droplet transfer over a limited range of travel speeds. At higher travel speeds, an unstable metal transfer mechanism was observed. Comparing leading arc and trailing arc arrangements, the leading arc configuration can provide higher quality welds and more stable processing at longer inter-distances between the heat sources.

Improved Method of Locating Defects in Wiring Insulation

NASA Technical Reports Server (NTRS)

Greulich, Owen R.

2004-01-01

An improved method of locating small breaches in insulation on electrical wires combines aspects of the prior dielectric withstand voltage (DWV) and time-domain reflectometry (TDR) methods. The method was invented to satisfy a need for reliably and quickly locating insulation defects in spacecraft, aircraft, ships, and other complex systems that contain large amounts of wiring, much of it enclosed in structures that make it difficult to inspect. In the DWV method, one applies a predetermined potential (usually 1.5 kV DC) to the wiring and notes whether the voltage causes any arcing between the wiring and ground. The DWV method does not provide an indication of the location of the defect (unless, in an exceptional case, the arc happens to be visible). In addition, if there is no electrically conductive component at ground potential within about 0.010 in. (approximately equal to 0.254 mm) of the wire at the location of an insulation defect, then the DWV method does not provide an indication of the defect. Moreover, one does not have the option to raise the potential in an effort to increase the detectability of such a defect because doing so can harm previously undamaged insulation. In the TDR method as practiced heretofore, one applies a pulse of electricity having an amplitude of less than 25 V to a wire and measures the round-trip travel time for the reflection of the pulse from a defect. The distance along the wire from the point of application of the pulse to the defect is then calculated as the product of half the round-trip travel time and the characteristic speed of a propagation of an electromagnetic signal in the wire. While the TDR method as practiced heretofore can be used to locate a short or open circuit, it does not ordinarily enable one to locate a small breach in insulation because the pulse voltage is too low to cause arcing and thus too low to induce an impedance discontinuity large enough to generate a measurable reflection. The present improved method overcomes the weaknesses of both the prior DWV and the prior TDR method.

Theoretical study of a consumable anode in a gas metal welding arc

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhu, P.; Simpson, S.W.

1996-12-31

A better understanding of the behavior of the metal transfer process in a welding arc is important for further improvement of quality control for gas-metal-arc welding (GMAW). The problems related to the metal transfer are generally complicated because (a) the metal transfer process is strongly coupled with the arc plasma, which is not stable, for example, the length of the arc plasma varies during the formation and detachment of a metal droplet, and (b) the formation of the electrode droplet itself is influenced by energy transfer, the anode-plasma interface, and also the location of the liquid-solid interface inside the anode.more » This paper presents primary results of an investigation of the consumable anode in a gas metal welding arc. The study includes theoretical predictions of the properties related to metal transfer including moving anode temperature profile, welding arc length and arc current as a function of time for various wire feed rates, as well as numerical treatment of droplet formation. The anode temperature profile and the melting rate are analyzed by a metal transfer model which couples a two-dimensional arc model to a one-dimensional anode thermal model. The droplet formation is predicted by a quasi-one-dimensional dynamic model of a pendant drop which accounts for the electromagnet pinch effect, the surface tension, gravitation and the momentum transfer due to wire motion. Comparison between experimental observation and theoretical predictions will also be discussed.« less

Performance Testing of Thermal Cutting Systems for Sweet Pepper Harvesting Robot in Greenhouse Horticulture

NASA Astrophysics Data System (ADS)

Bachche, Shivaji; Oka, Koichi

2013-03-01

This paper proposes design of end-effector and prototype of thermal cutting system for harvesting sweet peppers. The design consists of two parallel gripper bars mounted on a frame connected by specially designed notch plate and operated by servo motor. Based on voltage and current, two different types of thermal cutting system prototypes; electric arc and temperature arc respectively were developed and tested for performance. In electric arc, a special electric device was developed to obtain high voltage to perform cutting operation. At higher voltage, electrodes generate thermal arc which helps to cut stem of sweet pepper. In temperature arc, nichrome wire was mounted between two electrodes and current was provided directly to electrodes which results in generation of high temperature arc between two electrodes that help to perform cutting operation. In both prototypes, diameters of basic elements were varied and the effect of this variation on cutting operation was investigated. The temperature arc thermal system was found significantly suitable for cutting operation than electric arc thermal system. In temperature arc thermal cutting system, 0.5 mm nichrome wire shows significant results by accomplishing harvesting operation in 1.5 seconds. Also, thermal cutting system found suitable to increase shelf life of fruits by avoiding virus and fungal transformation during cutting process and sealing the fruit stem. The harvested sweet peppers by thermal cutting system can be preserved at normal room temperature for more than 15 days without any contamination.

Model-Based Testability Assessment and Directed Troubleshooting of Shuttle Wiring Systems

NASA Technical Reports Server (NTRS)

Deb, Somnath; Domagala, Chuck; Shrestha, Roshan; Malepati, Venkatesh; Cavanaugh, Kevin; Patterson-Hine, Ann; Sanderfer, Dwight; Cockrell, Jim; Norvig, Peter (Technical Monitor)

2000-01-01

We have recently completed a pilot study on the Space shuttle wiring system commissioned by the Wiring Integrity Research (WIRe) team at NASA Ames Research Center, As the space shuttle ages, it is experiencing wiring degradation problems including arcing, chaffing insulation breakdown and broken conductors. A systematic and comprehensive test process is required to thoroughly test and quality assure (QA) the wiring systems. The NASA WIRe team recognized the value of a formal model based analysis for risk-assessment and fault coverage analysis. However. wiring systems are complex and involve over 50,000 wire segments. Therefore, NASA commissioned this pilot study with Qualtech Systems. Inc. (QSI) to explore means of automatically extracting high fidelity multi-signal models from wiring information database for use with QSI's Testability Engineering and Maintenance System (TEAMS) tool.

Coating with overlay metallic-cermet alloy systems

NASA Technical Reports Server (NTRS)

Gedwill, M. A.; Levine, S. R.; Glasgow, T. K. (Inventor)

1984-01-01

A base layer of an oxide dispersed, metallic alloy (cermet) is arc plasma sprayed onto a substrate, such as a turbine blade, vane, or the like, which is subjected to high temperature use. A top layer of an oxidation, hot corrosion, erosion resistant alloy of nickel, cobalt, or iron is then arc plasma sprayed onto the base layer. A heat treatment is used to improve the bonding. The base layer serves as an inhibitor to interdiffusion between the protective top layer and the substrate. Otherwise, the 10 protective top layer would rapidly interact detrimentally with the substrate and degrade by spalling of the protective oxides formed on the outer surface at elevated temperatures.

Thermal spray for commercial shipbuilding

NASA Astrophysics Data System (ADS)

Rogers, F. S.

1997-09-01

Thermal spraying of steel with aluminum to protect it from corrosion is a technology that has been proven to work in the marine environment. The thermal spray coating system includes a paint sealer that is applied over the thermally sprayed aluminum. This extends the service life of the coating and provides color to the end product. The thermal spray system protects steel both through the principle of isolation (as in painting) and galvanizing. With this dual protection mechanism, steel is protected from corrosion even when the coating is damaged. The thermal- sprayed aluminum coating system has proved the most cost- effective corrosion protection system for the marine environment. Until recently, however, the initial cost of application has limited its use for general application. Arc spray technology has reduced the application cost of thermal spraying of aluminum to below that of painting. Commercial shipbuilders could use this technology to enhance their market position in the marine industry.

Effect of Auxiliary Preheating of the Filler Wire on Quality of Gas Metal Arc Stainless Steel Claddings

NASA Astrophysics Data System (ADS)

Shahi, Amandeep S.; Pandey, Sunil

2008-02-01

Weld cladding is a process for producing surfaces with good corrosion resistant properties by means of depositing/laying of stainless steels on low-carbon steel components with an objective of achieving maximum economy and enhanced life. The aim of the work presented here was to investigate the effect of auxiliary preheating of the solid filler wire in mechanized gas metal arc welding (GMAW) process (by using a specially designed torch to preheat the filler wire independently, before its emergence from the torch) on the quality of the as-welded single layer stainless steel overlays. External preheating of the filler wire resulted in greater contribution of arc energy by resistive heating due to which significant drop in the main welding current values and hence low dilution levels were observed. Metallurgical aspects of the as welded overlays such as chemistry, ferrite content, and modes of solidification were studied to evaluate their suitability for service and it was found that claddings obtained through the preheating arrangement, besides higher ferrite content, possessed higher content of chromium, nickel, and molybdenum and lower content of carbon as compared to conventional GMAW claddings, thereby giving overlays with superior mechanical and corrosion resistance properties. The findings of this study not only establish the technical superiority of the new process, but also, owing to its productivity-enhanced features, justify its use for low-cost surfacing applications.

The Optical Harness: a light-weight EMI-immune replacement for legacy electrical wiring harnesses

NASA Astrophysics Data System (ADS)

Stark, Jason B.; Jackson, B. Scott; Trethewey, William

2006-05-01

Electrical wiring harnesses have been used to interconnect control and communication equipment in mobile platforms for over a century. Although they have served this function successfully, they have three problems that are inherent in their design: they are mechanically heavy and stiff, and they are prone to electrical faults, including arcing and Electro-Magnetic Interference (EMI), and they are difficult to maintain when faults occur. These properties are all aspects of the metallic conductors used to build the harnesses. The Optical Harness TM is a photonic replacement for the legacy electrical wiring harness. The Optical Harness TM uses light-weight optical fiber to replace signal wires in an electrical harness. The original electrical connections to the equipment remain, making the Optical Harness TM a direct replacement for the legacy wiring harness. In the backshell of each connector, the electrical signals are converted to optical, and transported on optical fiber, by a deterministic, redundant and fault-tolerant optical network. The Optical Harness TM: * Provides weight savings of 40-50% and unsurpassed flexibility, relative to legacy signal wiring harnesses; * Carries its signals on optical fiber that is free from arcing, EMI, RFI and susceptibility to HPM weapons; * Is self-monitoring during operation, providing non-intrusive predictive and diagnostic capabilities.

In Process Measurement of Hydrogen in Welding

DTIC Science & Technology

1986-09-01

Specimen Geometry.........40 Figure 4.8 GTAW Diffusible Hydrogen Specimen Geometry .......... 40 Figure 4.9 Schematic of Specimen Outgassing Container for... GTAW ) and gas metal arc welding (GMAW) have the lowest potentials for hydrogen pickup, while -. the flux-cored arc welding (FCAW) and submerged arc...wire during welding which is the major source of hydrogen in GMAW and GTAW . Although the FCAW process was originally considered an intrinsi- cally low

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

NASA Technical Reports Server (NTRS)

Zaplatynsky, Isidor

1987-01-01

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.

Influence of laser on the droplet behavior in short-circuiting, globular, and spray modes of hybrid fiber laser-MIG welding

NASA Astrophysics Data System (ADS)

Cai, Chuang; Feng, Jiecai; Li, Liqun; Chen, Yanbin

2016-09-01

The effects of laser on the droplet behavior in short-circuiting, globular, and spray modes of hybrid fiber laser-MIG welding were studied. Transfer sequence of a droplet, welding current wave and morphology of plasma in the three modes of arc welding and hybrid welding were comparatively investigated. Compared with arc welding, the transfer frequency and landing location of droplet in the three modes of hybrid welding changed. In short-circuiting and globular modes, the droplet transfer was promoted by the laser, while the droplet transfer was hindered by the laser in spray mode. The magnitudes and directions of electromagnetic force and plasma drag force acting on the droplet were the keys to affect the droplet behavior. The magnitudes and directions of electromagnetic force and plasma drag force were converted due to the variation of the current distribution into the droplet, which were caused by the laser induced plasma with low ionization potential.

Estimation and control of droplet size and frequency in projected spray mode of a gas metal arc welding (GMAW) process.

PubMed

Anzehaee, Mohammad Mousavi; Haeri, Mohammad

2011-07-01

New estimators are designed based on the modified force balance model to estimate the detaching droplet size, detached droplet size, and mean value of droplet detachment frequency in a gas metal arc welding process. The proper droplet size for the process to be in the projected spray transfer mode is determined based on the modified force balance model and the designed estimators. Finally, the droplet size and the melting rate are controlled using two proportional-integral (PI) controllers to achieve high weld quality by retaining the transfer mode and generating appropriate signals as inputs of the weld geometry control loop. Copyright © 2011 ISA. Published by Elsevier Ltd. All rights reserved.

Development of a Catalytic Coating for a Shuttle Flight Experiment

NASA Technical Reports Server (NTRS)

Stewart, David A.; Goekcen, Tahir; Sepka, Steven E.; Leiser, Daniel B.; Rezin, Marc D.

2010-01-01

A spray-on coating was developed for use on the shuttle wing tiles to obtain data that could be correlated with computational fluid dynamics (CFD) solutions to better understand the effect of chemical heating on a fore-body heat shield having a turbulent boundary layer during planetary entry at hypersonic speed. The selection of a spray-on coating was conducted in two Phases 1) screening tests to select the catalytic coating formulation and 2) surface property determination using both arc-jet and side-arm facilities at NASA Ames Research Center. Comparison of the predicted surface temperature profile over a flat-plate with measured values obtained during arc-jet exposure (Phase I study) was used to validate the surface properties obtained during Phase II.

Corrosion Fatigue and Environmentally Assisted Cracking in Aging Military Vehicles (La fatigue-corrosion et la fissuration en milieu ambiant des vehicules militaires vieillissants)

DTIC Science & Technology

2011-03-01

deposition temperature is above 260°C (500°F), CVD Al cannot be applied to many structural alloys used in aerospace [12]. 23.3.4 Spray Deposited Cadmium...Alternatives There are several different aluminum-based coatings that can be deposited by spraying : aluminum and Al alloys , metallic-ceramic coatings...and Al - and Zn-filled polymers [12]. Thermal spray (flame or arc) is a very flexible and cost-effective process for deposition of pure

Corrosion Fatigue and Environmentally Assisted Cracking in Aging Military Vehicles (le fatigue-corrosion et la fissuration en milieu ambiant des vehicules militaires vieillissants)

DTIC Science & Technology

2011-03-01

deposition temperature is above 260°C (500°F), CVD Al cannot be applied to many structural alloys used in aerospace [12]. 23.3.4 Spray Deposited Cadmium...Alternatives There are several different aluminum-based coatings that can be deposited by spraying : aluminum and Al alloys , metallic-ceramic coatings...and Al - and Zn-filled polymers [12]. Thermal spray (flame or arc) is a very flexible and cost-effective process for deposition of pure

Arc driver operation for either efficient energy transfer or high-current generator

NASA Technical Reports Server (NTRS)

Dannenberg, R. E.; Silva, A. F.

1972-01-01

An investigation is made to establish predictable electric arcs along triggered paths for research purposes, the intended application being the heating of the driver gas of a 1 MJ electrically driven shock tube. Trigger conductors consisting of wires, open tubes, and tubes pressurized with different gases were investigated either on the axis of the arc chamber or spiraled along the chamber walls. Design criteria are presented for successful arc initiation with reproducible voltage-current characteristics. Results are compared with other facilities and several application areas are discussed.

Influence of the Gap Width on the Geometry of the Welded Joint in Hybrid Laser-Arc Welding

NASA Astrophysics Data System (ADS)

Turichin, G.; Tsibulskiy, I.; Kuznetsov, M.; Akhmetov, A.; Mildebrath, M.; Hassel, T.

The aim of this research was the experimental investigation of the influence of the gap width and speed of the welding wire on the changes of the geometry in the welded joint in the hybrid laser-arc welding of shipbuilding steel RS E36. The research was divided into three parts. First, in order to understand the influence of the gap width on the welded joint geometry, experimental research was done using continuous wave fiber laser IPG YLS-15000 with arc rectifier VDU-1500DC. The second part involved study of the geometry of the welded joint and hardness test results. Three macrosections from each welded joint were obtained. Influence of the gap width and welding wire speed on the welded joint geometry was researched in the three lines: in the right side of the plates, middle welded joint and in the root welded joint.

Analytical interpretation of arc instabilities in a DC plasma spray torch: the role of pressure

NASA Astrophysics Data System (ADS)

Rat, V.; Coudert, J. F.

2016-06-01

Arc instabilities in a plasma spray torch are investigated experimentally and theoretically thanks to a linear simplified analytical model. The different parameters that determine the useful properties of the plasma jet at the torch exit, such as specific enthalpy and speed, but also pressure inside the torch and time variations of the flow rate are studied. The work is particularly focused on the link between the recorded arc voltage and the pressure in the cathode cavity. A frequency analysis of the recorded voltage and pressure allows the separation of different contributions following their spectral characteristics and highlights a resonance effect due to Helmholtz oscillations; these oscillations are responsible for the large amplitude fluctuations of all the parameters investigated. The influence of heat transfer, friction forces and residence time of the plasma in the nozzle are taken into account, thanks to different characteristics’ times. The volume of the cathode cavity in which the cold gas is stored before entering the arc region appears to be of prime importance for the dynamics of instabilities, particularly for the non-intuitive effect that induces flow-rate fluctuations in spite of the fact that the torch is fed at a constant flow rate.

75 FR 24389 - Airworthiness Directives; Bombardier, Inc. Model DHC-8-400 Series Airplanes

Federal Register 2010, 2011, 2012, 2013, 2014

2010-05-05

... concern. * * * * * Loss of both AC generators could lead to unannunciated loss of heat to both engine... protruding stems which chafed through the wire insulation leading to arcing damage. In addition, the wire... shroud. Loss of both AC generators could lead to unannunciated loss of heat to both engine inlets, which...

78 FR 59304 - Airworthiness Directives; The Boeing Company Airplanes

Federal Register 2010, 2011, 2012, 2013, 2014

2013-09-26

... ducting with smoke and fire. Incorrectly installed metal clamps, if not corrected, could cause wire bundle... with smoke and fire caused by metal clamps installed on certain hoses. We are issuing this AD to... chaffing, arcing, and burning damage to the control cabin overhead wiring and ducting with smoke and fire...

Numerical analysis on temperature field in single-wire flux-aided backing-submerged arc welding

NASA Astrophysics Data System (ADS)

Pu, Juan; Wu, Ming Fang; Pan, Haichao

2017-07-01

Single-wire flux-aided backing-submerged arc welding (FAB-SAW) technology has been widely used to weld thick steel plate due to its easy assembly and high heat input. The microstructure and property of welded joint are closely related to the thermal field of FAB-SAW process. In this research, the feature of thermal field for single-wire FAB-SAW was investigated. Based on the heat transfer mechanism, a three-dimensional transient model for thermal field was developed based on the influence of steel thickness, groove angle and ceramic backing. The temperature profile in single-wire FAB-SAW of D36 steel under different welding conditions was simulated by ANSYS. The characteristic of thermal field was analyzed and the influences of groove angle on temperature field for different plate thicknesses were discussed. The calculated geometries and dimensions of weld cross-section under different conditions show a good agreement with the experimental results. This newly built model can describe the thermal field accurately, which would be helpful to understanding the thermophysical mechanism of FAB-SAW and optimizing the welding process.

Hot-wire Laser Welding of Deep and Wide Gaps

NASA Astrophysics Data System (ADS)

Näsström, J.; Frostevarg, J.; Silver, T.

Heavy section Gas Metal Arc Welding (GMAW) usually requires special edge preparation and several passes. One alternative for increased performance is Laser Arc Hybrid Welding (LAHW). For very thick sheets however, imperfections like root drops or solidification cracks can occur. In this study, other techniques are also studied, including multi-pass filling of deep gaps with wire deposition. A laser is then used to melt the filler and base material. The hot- and cold wire laser welding processes are highly sensitive to wire-laser positioning, where controlled melting of the wire is essential. Apart from a comprehensive literature survey, preliminary experiments were also performed in order to find a novel method variant that can successfully fill deep and wide gaps. The method applied uses a defocused laser that generates the melt pool. A resistance heated wire is fed into the melt pool front in a leading position. This is similar to additive manufacturing techniques such as laser direct metal deposition with wire. A layer height of several millimeters can be achieved and rather low laser power can be chosen. The preliminary experiments were observed using high speed imaging and briefly evaluated by visual examination of the resulting beads. Using a defocused laser beam turned out to have two major advantages; 1. It adds heat to the melt pool in a manner that properly fuses the bottom and walls of the base material. 2. It counteracts difficulties due to an irregularly oscillating filler wire. These early results show that this can be a promising technique for joining thick steels with wide gaps.

Study of the welding gas influence on a controlled short-arc GMAW process by optical emission spectroscopy

NASA Astrophysics Data System (ADS)

Wilhelm, G.; Gött, G.; Schöpp, H.; Uhrlandt, D.

2010-11-01

The controlled short-arc processes, variants of the gas metal arc welding (GMAW) process, which have recently been developed, are used to reduce the heat input into the workpiece. Such a process with a wire feeding speed which varies periodically, using a steel wire and a steel workpiece to produce bead-on-plate welds has been investigated. As welding gases CO2 and a mixture of Ar and O2 have been used. Depending on the gas, the properties of the plasma change, and as a consequence the weldseams themselves also differ distinctly. Optical emission spectroscopy has been applied to analyse the plasma. The radial profiles of the emission coefficients of an iron line and an argon line or an atomic oxygen line, respectively, have been determined. These profiles indicate the establishment of a metal vapour arc core which has a broader profile under CO2 but is more focused in the centre for argon. The measured iron line emission was near to its norm maximum in the case of CO2. From this fact, temperatures around 8000 K and a metal vapour molar fraction above 75% in the arc centre could be roughly estimated for this case. Estimations of the electrical conductivity and the arc field indicate that the current path must include not only the metal vapour arc core but also outer hot regions dominated by welding gas properties in the case of argon.

Development of circuit model for arcing on solar panels

NASA Astrophysics Data System (ADS)

Mehta, Bhoomi K.; Deshpande, S. P.; Mukherjee, S.; Gupta, S. B.; Ranjan, M.; Rane, R.; Vaghela, N.; Acharya, V.; Sudhakar, M.; Sankaran, M.; Suresh, E. P.

2010-02-01

The increased requirements of payload capacity of the satellites have resulted in much higher power requirements of the satellites. In order to minimize the energy loss during power transmission due to cable loss, use of high voltage solar panels becomes necessary. When a satellite encounters space plasma it floats negatively with respect to the surrounding space plasma environment. At high voltage, charging and discharging on solar panels causes the power system breakdown. Once a solar panel surface is charged and potential difference between surface insulator and conductor exceeds certain value, electrostatic discharge (ESD) may occur. This ESD may trigger a secondary arc that can destroy the solar panel circuit. ESD is also called as primary or minor arc and secondary is called major arc. The energy of minor arc is supplied by the charge stored in the coverglass of solar array and is a pulse of typically several 100 ns to several 100 μs duration. The damage caused by minor arc is less compared to major arcs, but it is observed that the minor arc is cause of major arc. Therefore it is important to develop an understanding of minor arc and mitigation techniques. In this paper we present a linear circuit analysis for minor arcs on solar panels. To study arcing event, a ground experimental facility to simulate space plasma environment has been developed at Facilitation Centre for Industrial Plasma Technologies (Institute for Plasma Research) in collaboration with Indian Space Research Organization's ISRO Satellite Technology Centre (ISAC). A linear circuit model has been developed to explain the experimental results by representing the coverglass, solar cell interconnect and wiring by an LCR circuit and the primary arc by an equivalent LR circuit. The aim of the circuit analysis is to predict the arc current which flows through the arc plasma. It is established from the model that the current depends on various parameters like potential difference between insulator and conductor, arc resistance, stored charge in the solar cell coverglass and the external capacitor that simulates wire harness. A close correlation between the experiments and circuit model results has been observed.

NASA wiring for space applications program

NASA Technical Reports Server (NTRS)

Schulze, Norman

1995-01-01

An overview of the NASA Wiring for Space Applications Program and its relationship to NASA's space technology enterprise is given in viewgraph format. The mission of the space technology enterprise is to pioneer, with industry, the development and use of space technology to secure national economic competitiveness, promote industrial growth, and to support space missions. The objectives of the NASA Wiring for Space Applications Program is to improve the safety, performance, and reliability of wiring systems for space applications and to develop improved wiring technologies for NASA flight programs and commercial applications. Wiring system failures in space and commercial applications have shown the need for arc track resistant wiring constructions. A matrix of tests performed versus wiring constructions is presented. Preliminary data indicate the performance of the Tensolite and Filotex hybrid constructions are the best of the various candidates.

METAL SPRAYER FOR USE IN VACUUM OR INERT ATMOSPHERE

DOEpatents

Monroe, R.E.

1958-10-14

A metal sprayer is described for use in a vacuum or inert atmosphere with a straight line wire feed and variable electrode contact angle. This apparatus comprises two wires which are fed through straight tubes of two mechanisms positioned on opposite sides of a central tube to which an inert gas is fed. The two mechanisms and the wires being fed constitute electrodes to which electrical current is supplied so that the wires are melted by the electric are formed at their contacting region and sprayed by the gas supplied by the central tube. This apparatus is designed specifically to apply a zirconium coating to uranium in an inert atmosphere and without the use of an oxidizing flame.

THERMAL RELAY DEVICE

DOEpatents

Murdoch, R.O.; Record, F.A.

1963-01-29

This invention relates to a fast-acting spring-loaded electrical switch which can break a 1500-volt circuit in one millisecond without arcing. In particular, a springloaded shorting bar is held in tension by a fusible wire. Passage of an electrical current pulse through the fusible wire breaks the fuse thereby releasing the shorting bar to open one and close another electrical circuit. (AEC)

Performance of Zinc Anodes for Cathodic Protection of Reinforced Concrete Bridges

DOE Office of Scientific and Technical Information (OSTI.GOV)

Covino, Bernard S. Jr.; Cramer, Stephen D.; Bullard, Sophie J.

2002-03-01

Operation of thermal spray zinc (Zn) anodes for cathodic protection (CP) of reinforced concrete structures was investigated in laboratory and field studies conducted by the Albany Research Center (ARC) in collaboration with the Oregon Department of Transportation. The purposes of the research presented in this report were: evaluate the need for preheating concrete to improve the adhesion of the anode; estimate the service life of thermal spray Zn CP anodes; determine the optimum thickness for Zn CP anodes; characterize the anode-concrete interfacial chemistry; and correlate field and laboratory results. Laboratory studies involved accelerated electrochemical aging of thermal sprayed Zn anodesmore » on concrete slabs, some of which were periodically wetted while others were unwetted. Concrete used in the slabs contained either 1.2 or 3 kg NaCl /m3 (2 or 5 lbs NaCl /yd3) as part of the concrete mix design. The Zn anodes were applied to the slabs using the twin wire arc-spray technique. Half of the slabs were preheated to 120-160 C (250-320 F) to improve the initial Zn anode bond strength and the other half were not. Accelerated aging was done at a current density of 0.032 A/m2 (3 mA/ft2), 15 times that used on Oregon DOT Coastal bridges, i.e, . 0.0022 A/m2 (0.2 mA/ft2) Cores from the Cape Creek Bridge (OR), the Richmond San Rafael Bridge (CA), and the East Camino Underpass (CA) were used to study the anode-concrete interfacial chemistry, to relate the chemistry to electrochemical age at the time of sampling, and to compare the chemistry of the field anodes to the chemistry of anodes from the laboratory studies. Cores from a CALTRANS study of a silane sealant used prior to the application of the Zn anodes and cores with galvanized rebar from the Longbird Bridge (Bermuda) were also studied. Aged laboratory and field anodes were characterized by measuring some or all of the following parameters: thickness, bond strength, anode-concrete interfacial chemistry, bulk chemistry, anode resistance, circuit resistance, electrochemical age, and air and water permeability. Models are presented for the operation of periodically-wetted and unwetted thermal spray Zn anodes from the initial energizing of the anode to the end of its service life. The models were developed in terms of bond strength, circuit resistance, anode-concrete interfacial chemistry, electrochemical age, and anode condition. The most significant results of the research are: (1) preheating concrete surfaces prior to coating with Zn is unnecessary; (2) anodes generally fail due to loss of bond strength rather than Zn consumption; (3) Unwetted anodes fail more quickly than periodically-wetted anodes; (4) 0.47-0.60 mm (12-15 mil) anode thickness is adequate for most Oregon DOT coastal impressed current CP (ICCP) installations; (5) based on bond strength, thermal spray Zn ICCP anode service life is approximately 27 years at 0.0022 A/m2 (0.2 mA/ft2); (6) anode reaction products alter the anode-concrete interface by rejecting Ca from the cement paste, by replacing it with Zn, and by the accumulation of a Zn mineral layer that includes chloride and sulfur compounds; (7) CP system circuit resistance provides an effective means for monitoring the condition of Zn ICCP anodes as they age.« less

Preparation and Bond Properties of Thermal Barrier Coatings on Mg Alloy with Sprayed Al or Diffused Mg-Al Intermetallic Interlayer

NASA Astrophysics Data System (ADS)

Fan, Xizhi; Wang, Ying; Zou, Binglin; Gu, Lijian; Huang, Wenzhi; Cao, Xueqiang

2014-02-01

Sprayed Al or diffused Mg-Al layer was designed as interlayer between the thermal barrier coatings (TBCs) and Mg alloy substrate. The effects of the interlayer on the bond properties of the coats were investigated. Al layers were prepared by arc spraying and atmospheric plasma spraying (APS), respectively. Mg-Al diffused layer was obtained after the heat treatment of the sprayed sample (Mg alloy with APS Al coat) at 400 °C. The results show that sprayed Al interlayer does not improve the bond stability of TBCs. The failure of the TBCs on Mg alloy with Al interlayer occurs mainly due to the low strength of Al layer. Mg-Al diffused layer improves corrosion resistance of substrate and the bond interface. The TBCs on Mg alloy with Mg-Al diffused interlayer shows better bond stability than the sample of which the TBCs is directly sprayed on Mg alloy substrate by APS.

Control of arc length during gas metal arc welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Madigan, R.B.; Quinn, T.P.

1994-12-31

An arc-length control system has been developed for gas metal arc welding (GMAW) under spray transfer welding conditions. The ability to monitor and control arc length during arc welding allows consistent weld characteristics to be maintained and therefore improves weld quality. Arc length control has only been implemented for gas tungsten arc welding (GTAW), where an automatic voltage control (AVC) unit adjusts torch-to-work distance. The system developed here compliments the voltage- and current-sensing techniques commonly used for control of GMAW. The system consists of an arc light intensity sensor (photodiode), a Hall-effect current sensor, a personal computer and software implementingmore » a data interpretation and control algorithms. Arc length was measured using both arc light and arc current signals. Welding current was adjusted to maintain constant arc length. A proportional-integral-derivative (PID) controller was used. Gains were automatically selected based on the desired welding conditions. In performance evaluation welds, arc length varied from 2.5 to 6.5 mm while welding up a sloped workpiece (ramp in CTWD) without the control. Arc length was maintained within 1 mm of the desired (5 mm ) with the control.« less

SUMMARY OF THE SEVENTH MEETING OF THE REFRACTORY COMPOSITES WORKING GROUP

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gibeaut, W.A.; Ogden, H.R.

1963-05-30

Information on refractory composites for use above 2500 deg F is summarized. Reports are concerned with protective coatings, insulating ceramics, materials for rocket thrust chambers, dispersion strengthening of metals, joining of refractory materials, and testing techniques. The problem of accelerated failure of silicide coatings under conditions of very low air pressure at high temperatures is studied. Although the maximum temperature capability of most silicide coatings is reduced about 50 theta deg at low air pressures, several coatings can protect molybdenum for 1/2 hr at 2800 to 3000 deg F under these conditions. The tin-aluminum coating also is susceptible to earlymore » failure at reduced pressure. An evaluation of the mechanical properties of 6-mil foils of D- 36, B-68, and TZM coated with commercial coatings demonstrated that some coatings seriously degrade substrate mechanical properties. Research on thermal- protection systems for re-entry vehicles whose surface temperatures reach from 3300 to 5500 deg F has resulted in agreement upon oxide coatings and thick metal- reinforced oxide composites. Simple plasmaarc-sprayed oxide coatings have demonstrated adequate oxidation resistance, but their structural stability in cyclic thermal exposure is inferior to metal-reinforced oxide. Thin unreinforced oxide coatings tend to spall in tests involving cyclic heating. A metal- reinforced oxide composite (reinforcement welded to substrate) has survived cyclic tests such as five 3-minute exposures at 4500 deg F without failing. A new carbon material called glassy carbon has demonstrnted better oxidation resistance than pyrolytic graphite at very high temperatures. The erosion resistance of pyrolytic graphite coatings on regular graphite in rocket firing tests using solid propellants is encouraging. There is considerable interest in fabricating small radiation-cooled rocket thrust chambers by plasma arc spraying. The design concept of internal reinforcement of sprayed-metal rocket chambers with wrought ductile wife appears impractical because of poor bonding and porosity around the wire. (auth)« less

Autonomous diagnostics and prognostics of signal and data distribution systems

NASA Astrophysics Data System (ADS)

Blemel, Kenneth G.

2001-07-01

Wiring is the nervous system of any complex system and is attached to or services nearly every subsystem. Damage to optical wiring systems can cause serious interruptions in communication, command and control systems. Electrical wiring faults and failures due to opens, shorts, and arcing probably result in adverse effects to the systems serviced by the wiring. Abnormalities in a system usually can be detected by monitoring some wiring parameter such as vibration, data activity or power consumption. This paper introduces the mapping of wiring to critical functions during system engineering to automatically define the Failure Modes Effects and Criticality Analysis. This mapping can be used to define the sensory processes needed to perform diagnostics during system engineering. This paper also explains the use of Operational Modes and Criticality Effects Analysis in the development of Sentient Wiring Systems as a means for diagnostic, prognostics and health management of wiring in aerospace and transportation systems.

Method for minimizing decarburization and other high temperature oxygen reactions in a plasma sprayed material

DOEpatents

Lenling, William J.; Henfling, Joseph A.; Smith, Mark F.

1993-06-08

A method is disclosed for spray coating material which employs a plasma gun that has a cathode, an anode, an arc gas inlet, a first powder injection port, and a second powder injection port. A suitable arc gas is introduced through the arc gas inlet, and ionization of the arc gas between the cathode and the anode forms a plasma. The plasma is directed to emenate from an open-ended chamber defined by the boundary of the anode. A coating is deposited upon a base metal part by suspending a binder powder within a carrier gas that is fed into the plasma through the first powder injection port; a material subject to degradation by high temperature oxygen reactions is suspended within a carrier gas that is fed into the plasma through the second injection port. The material fed through the second injection port experiences a cooler portion of the plasma and has a shorter dwell time within the plasma to minimize high temperature oxygen reactions. The material of the first port and the material of the second port intermingle within the plasma to form a uniform coating having constituent percentages related to the powder-feed rates of the materials through the respective ports.

Venom-spraying behavior of the scorpion Parabuthus transvaalicus (Arachnida: Buthidae).

PubMed

Nisani, Zia; Hayes, William K

2015-06-01

Many animals use chemical squirting or spraying behavior as a defensive response. Some members of the scorpion genus Parabuthus (family Buthidae) can spray their venom. We examined the stimulus control and characteristics of venom spraying by Parabuthus transvaalicus to better understand the behavioral context for its use. Venom spraying occurred mostly, but not always, when the metasoma (tail) was contacted (usually grasped by forceps), and was absent during stinging-like thrusts of the metasoma apart from contact. Scorpions were significantly more likely to spray when contact was also accompanied by airborne stimuli. Sprays happened almost instantaneously following grasping by forceps (median=0.23s) as a brief (0.07-0.30s, mean=0.18s), fine stream (<5° arc) that was not directed toward the stimulus source; however, rapid independent movements of the metasoma and/or telson (stinger) often created a more diffuse spray, increasing the possibility of venom contact with the sensitive eyes of potential scorpion predators. Successive venom sprays varied considerably in duration and velocity. Collectively, these results suggest that venom spraying might be useful as an antipredator function and can be modulated based on threat. Copyright © 2015 Elsevier B.V. All rights reserved.

A Case Study on the Failure on Apollo 13

NASA Technical Reports Server (NTRS)

Anderson, Brenda Lindley

2011-01-01

Summary of Findings: (1) The post-failure investigation determined that extended operation of the heater damaged the wiring inside O2 #2. (2) Apparently during other stir operations prior to the explosion, the damaged wires didn't come in contact enough to spark. The right conditions had to be in position to cause the arcing which led to the blast.

Effect of Molten Pool Size on Microstructure and Tensile Properties of Wire Arc Additive Manufacturing of Ti-6Al-4V Alloy.

PubMed

Wu, Qianru; Lu, Jiping; Liu, Changmeng; Fan, Hongli; Shi, Xuezhi; Fu, Jie; Ma, Shuyuan

2017-07-04

Wire arc additive manufacturing (WAAM) technique is a cost-competitive and efficient technology to produce large structure components in industry domains. Mechanical properties are mainly dominated by the microstructure of the components, which is deeply affected by the molten pool size. In this work, to investigate the effect of the molten pool size on microstructure and mechanical properties of the components, a series of Ti-6Al-4V alloy blocks with different width of molten pool (WMP) ranging from 7 mm to 22 mm were deposited by adjusting the wire feed speed (WFS) from 100 cm/min to 500 cm/min. It is interesting to find that the macrostructure changes from columnar grains to equiaxial grains, and then returns to large columnar grains with the increase of WMP, which is mainly caused by the different cooling rates and thermal gradients. Nonetheless, the tensile properties of the components have a tendency to decline with the increase of WMP.

Effect of Molten Pool Size on Microstructure and Tensile Properties of Wire Arc Additive Manufacturing of Ti-6Al-4V Alloy

PubMed Central

Wu, Qianru; Lu, Jiping; Liu, Changmeng; Fan, Hongli; Shi, Xuezhi; Fu, Jie; Ma, Shuyuan

2017-01-01

Wire arc additive manufacturing (WAAM) technique is a cost-competitive and efficient technology to produce large structure components in industry domains. Mechanical properties are mainly dominated by the microstructure of the components, which is deeply affected by the molten pool size. In this work, to investigate the effect of the molten pool size on microstructure and mechanical properties of the components, a series of Ti-6Al-4V alloy blocks with different width of molten pool (WMP) ranging from 7 mm to 22 mm were deposited by adjusting the wire feed speed (WFS) from 100 cm/min to 500 cm/min. It is interesting to find that the macrostructure changes from columnar grains to equiaxial grains, and then returns to large columnar grains with the increase of WMP, which is mainly caused by the different cooling rates and thermal gradients. Nonetheless, the tensile properties of the components have a tendency to decline with the increase of WMP. PMID:28773107

Microstructures and mechanical properties of bonding layers between low carbon steel and alloy 625 processed by gas tungsten arc welding

NASA Astrophysics Data System (ADS)

Lou, Shuai; Lee, Seul Bi; Nam, Dae-Geun; Choi, Yoon Suk

2017-11-01

A filler metal wire, Alloy 625, was cladded on a plate of a low carbon streel, SS400, by gas tungsten arc welding, and the morphology of the weld bead and resulting dilution ratio were investigated under different welding parameter values (the input current, weld speed and wire feed speed). The wire feed speed was found to be most influential in controlling the dilution ratio of the weld bead, and seemed to limit the influence of other welding parameters. Two extreme welding conditions (with the minimum and maximum dilution ratios) were identified, and the corresponding microstructures, hardness and tensile properties near the bond line were compared between the two cases. The weld bead with the minimum dilution ratio showed superior hardness and tensile properties, while the formation lath martensite (due to relatively fast cooling) affected mechanical properties in the heat affected zone of the base metal with the maximum dilution ratio.

Aerospace Robotic Implementations: An Assessment and Forecast. Phase 2,

DTIC Science & Technology

1986-09-01

Spray Painting Robotic spray painting is a mature technology, and has been in use for several decades in places such as the automobile industry. The...to reprogrammability in applications where hard automation is too expensive for the volume. 3.2 Hybrid Circuit Assembly * Hybrid circuits require...1.1.1.2 2.1.4 Task Performed : LIGHT-STRIP ASSISTED ARC WELD DRILL,GRIND, INSPCOMPOSITES Other Comments • AUTOMOBILE TRAILING AXLEAPPL. CASPIN MANTECH

dc-plasma-sprayed electronic-tube device

DOEpatents

Meek, T.T.

1982-01-29

An electronic tube and associated circuitry which is produced by dc plasma arc spraying techniques is described. The process is carried out in a single step automated process whereby both active and passive devices are produced at very low cost. The circuitry is extremely reliable and is capable of functioning in both high radiation and high temperature environments. The size of the electronic tubes produced are more than an order of magnitude smaller than conventional electronic tubes.

Two-dimensional time-dependent modelling of fume formation in a pulsed gas metal arc welding process

NASA Astrophysics Data System (ADS)

Boselli, M.; Colombo, V.; Ghedini, E.; Gherardi, M.; Sanibondi, P.

2013-06-01

Fume formation in a pulsed gas metal arc welding (GMAW) process is investigated by coupling a time-dependent axi-symmetric two-dimensional model, which takes into account both droplet detachment and production of metal vapour, with a model for fume formation and transport based on the method of moments for the solution of the aerosol general dynamic equation. We report simulative results of a pulsed process (peak current = 350 A, background current 30 A, period = 9 ms) for a 1 mm diameter iron wire, with Ar shielding gas. Results showed that metal vapour production occurs mainly at the wire tip, whereas fume formation is concentrated in the fringes of the arc in the spatial region close to the workpiece, where metal vapours are transported by convection. The proposed modelling approach allows time-dependent tracking of fumes also in plasma processes where temperature-time variations occur faster than nanoparticle transport from the nucleation region to the surrounding atmosphere, as is the case for most pulsed GMAW processes.

Second NASA Workshop on Wiring for Space Applications

NASA Technical Reports Server (NTRS)

1994-01-01

This document contains the proceedings of the Second NASA Workshop on Wiring for Space Applications held at NASA LeRC in Cleveland, OH, 6-7 Oct. 1993. The workshop was sponsored by NASA Headquarters Code QW Office of Safety and Mission Quality, Technical Standards Division and hosted by NASA LeRC, Power Technology Division, Electrical Components and Systems Branch. The workshop addressed key technology issues in the field of electrical power wiring for space applications. Speakers from government, industry, and academia presented and discussed topics on arc tracking phenomena, wiring system design, insulation constructions, and system protection. Presentation materials provided by the various speakers are included in this document.

Palladium-chromium static strain gages for high temperatures

NASA Technical Reports Server (NTRS)

Lei, Jih-Fen

1992-01-01

An electrical resistance strain gage that can provide accurate static strain measurement to a temperature of 1500 F or above is being developed both in fine wire and thin film forms. The gage is designed to be temperature compensated on any substrate material. It has a dual element: the gage element is a special alloy, palladium-13wt percent chromium (PdCr), and the compensator element is platinum (Pt). Earlier results of a PdCr based wire gage indicated that the apparent strain of this gage can be minimized and the repeatability of the apparent strain can be improved by prestabilizing the gage on the substrate for a long period of time. However, this kind of prestabilization is not practical in many applications and therefore the development of a wire gage which is prestabilized before installation on the substrate is desirable. This paper will present our recent progress in the development of a prestabilized wire gage which can provide meaningful strain data for the first thermal cycle. A weldable PdCr gage is also being developed for field testing where conventional flame-spraying installation can not be applied. This weldable gage is narrower than a previously reported gage, thereby allowing the gage to be more resistant to buckling under compressive loads. Some preliminary results of a prestabilized wire gage flame-sprayed directly on IN100, an engine material, and a weldable gage spot-welded on IN100 and SCS-6/(beta)21-S Titanium Matrix Composite (TMC), a National Aero-Space Plane (NASP) structure material, will be reported. Progress on the development of a weldable thin film gage will also be addressed. The measurement technique and procedures and the lead wire effect will be discussed.

Hydrogen mitigation in submerged arc welding

NASA Astrophysics Data System (ADS)

Klimowicz, Steven

With the role of hydrogen in weld metal well understood in its relation to cold cracking, there has been a push to produce welds with lower and lower diffusible hydrogen contents. The push for lower diffusible hydrogen contents has placed pressure on consumables manufactures to create consumables that can achieve the requirements for lower diffusible hydrogen content. Currently EM12K flux is produced so that it can achieve below 4 ml of diffusible hydrogen for every 100g of weld metal deposited (ml/100g) for submerged arc welding (SAW). The recent trend for industry is to preferentially achieve diffusible hydrogen contents below 3 ml/100g. Making it necessary to find a way to modify the flux to achieve a lower diffusible hydrogen content for the welds it produces. To achieve this goal a two phase plan was developed. The first phase was to characterize the entire welding system for hydrogen. Since the goal of the project is hydrogen mitigation, any amount of hydrogen that could be reduced is helpful and therefore must first be discovered. Sources of hydrogen may be found by analyzing the welding wire and base metal, as well as breaking the flux down into its components and production steps. The wire was analyzed for total hydrogen content as was the base metal. The flux and its components were analyzed using differential thermal analysis-simultaneous thermal analysis (DTA-STA) and later vacuum degassing for moisture content. The analysis of the wire showed that the copper coating on the wire was the largest contributor of hydrogen. There was lubricant present on the wire surface as well, but it did not contribute as much as the copper coating. It was found that a simple low temperature baking of the wire was enough to remove the lubricant and coating moisture. The base metal was found to have a similar total hydrogen content to that of the wire. The breakdown of the flux and production process for moisture content analysis revealed that the production process removes the moisture that is added by the water based binder. The second phase of the project was to modify the flux with fluoride additions to remove hydrogen from the arc while welding. The introduction of fluorine into the arc would lower the amount of hydrogen that may be absorbed as diffusible hydrogen by the weld metal. To select the fluorides a series of thermodynamic calculations were performed as well as simple tests to determine the fluorides behavior in a welding arc and flux. From these tests the following fluorides were selected to be used to be added to EM12K flux as oneweight percent additions: SrF 2, K2TiF6, K2SiF6, and LiF. Welds were then run with the experimental fluxes according to AWS A4.3 standard for diffusible hydrogen testing. From these tests it was found that none experimental fluxes were able to achieve a diffusible hydrogen content lower than the original EM12K flux. It was also found that fluoride reduction in a simple flux is a better predictor of fluoride effectiveness than decomposition temperature.

A Study on the Deposition of Al2O3 Coatings on Polymer Substrates by a Plasma Spray/Micro-Arc Oxidation Two-Step Method

NASA Astrophysics Data System (ADS)

Sun, Guanhong; He, Xiaodong; Jiang, Jiuxing; Sun, Yue; Zhong, Yesheng

2013-02-01

To increase the wear resistance of polymer matrix composites, alumina coatings were deposited on polymer substrates by a two-step method combining plasma spraying and micro-arc oxidation. The microstructures and phase compositions of the processed coatings were investigated for different treatment times. Uniformly distributed pores were found in addition to the presence of various coral-like structures and floccules on the surface of the coatings. The presence of α-Al2O3 and γ-Al2O3 phases was identified by XRD. The distribution of alumina was analyzed by EDS and is discussed. The maximum bond strength of the coatings was found to be 5.89 MPa. There was little thermal damage in the polymer substrates after the coatings were produced.

Futurepath: The Story of Research and Technology at NASA Lewis Research Center. Structures for Flight Propulsion, ARC Sprayed Monotape, National Aero-Space Plane

NASA Technical Reports Server (NTRS)

1989-01-01

The story of research and technology at NASA Lewis Research Center's Structures Division is presented. The job and designs of the Structures Division needed for flight propulsion is described including structural mechanics, structural dynamics, fatigue, and fracture. The video briefly explains why properties of metals used in structural mechanics need to be tested. Examples of tests and simulations used in structural dynamics (bodies in motion) are briefly described. Destructive and non-destructive fatigue/fracture analysis is also described. The arc sprayed monotape (a composite material) is explained, as are the programs in which monotape plays a roll. Finally, the National Aero-Space Plane (NASP or x-30) is introduced, including the material development and metal matrix as well as how NASP will reduce costs for NASA.

Moisture contamination and welding parameter effects on flux cored arc welding diffusible hydrogen

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kiefer, J.J.

1994-12-31

Gas metal arc (GMAW) and flux cored arc (FCAW) welding are gas shielded semiautomatic processes widely used for achieving high productivity in steel fabrication. Contamination of the shielding has can occur due to poorly maintained gas distribution systems. Moisture entering as a gas contaminant is a source of hydrogen that can cause delayed cold cracking in welds. Limiting heat-affected zone hardness is one method of controlling cracking. Even this is based on some assumptions about the hydrogen levels in the weld. A study was conducted to investigate the effect of shielding gas moisture contamination and welding parameters on the diffusiblemore » hydrogen content of gas shielded flux cored arc welding. The total wire hydrogen of various electrodes was also tested and compared to the diffusible weld hydrogen. An empirical equation has been developed that estimates the diffusible hydrogen in weld metal for gas shielded flux cored arc welding. The equation is suitable for small diameter electrodes and welding parameter ranges commonly used for out-of-position welding. by combining this with the results from the total wire hydrogen tests, it is possible to estimate diffusible hydrogen directly from measured welding parameters, shielding gas dew point, and total hydrogen of the consumable. These equations are also useful for evaluating the effect of welding procedure variations from known baseline conditions.« less

Alternative Gas Mixtures in Arc Spraying: A Chance to Improve Coating Properties and Residual Stress States

NASA Astrophysics Data System (ADS)

Hauer, Michél; Henkel, Knuth Michael; Krebs, Sebastian; Kroemmer, Werner

2018-01-01

The highly cavitation erosion-resistant propeller alloys CuAl9Ni5Fe4Mn (Ni-Al-Bronze) and CuMn13Al8Fe3Ni2 (Mn-Al-Bronze) were arc-sprayed using a mixture of nitrogen and 2% of hydrogen as atomizing gas and different traverse speeds. The objective was to identify the influences of the different spraying conditions, such as temperature regime and melting loss, on the resulting residual stress states and coating properties. Residual stresses were measured by the incremental hole-drilling method using ESPI. Temperature measurements were carried out by thermographic imaging. Microstructural, chemical and mechanical analyses were realized to examine adhesive and cohesive properties. Additionally, the cavitation erosion behavior was investigated to analyze cohesive coating properties. The spraying process itself was improved, which was apparent by mainly enhanced deposition efficiency and reduced surface temperatures. The amount of oxides and pores as well as the melting loss of alloying elements were reduced. Moreover, an increased cavitation erosion resistance and thus coating cohesion as well as less residual stresses were identified. The change in atomizing gas diminished the impact of the quenching stresses on the coating properties. In contrast, the adhesive strength, Young's moduli and partially the hardness were slightly reduced. With regard to materials, Ni-Al-Bronze revealed superior coating properties in comparison with Mn-Al-Bronze.

First NASA Workshop on Wiring for Space Applications

NASA Technical Reports Server (NTRS)

Hammond, Ahmad (Compiler); Stavnes, Mark W. (Compiler)

1994-01-01

This document contains the proceedings of the First NASA Workshop on Wiring for Space Applications held at NASA Lewis Research Center in Cleveland, OH, July 23-24, 1991. The workshop was sponsored by NASA Headquarters Code QE Office of Safety and Mission Quality, Technical Standards Division and hosted by the NASA Lewis Research Center, Power Technology Division, Electrical Components and Systems Branch. The workshop addressed key technology issues in the field of electrical power wiring for space applications. Speakers from government, industry and academia presented and discussed topics on arc tracking phenomena, wiring applications and requirements, and new candidate insulation materials and constructions. Presentation materials provided by the various speakers are included in this document.

Time resolved Thomson scattering diagnostic of pulsed gas metal arc welding (GMAW) process

NASA Astrophysics Data System (ADS)

Kühn-Kauffeldt, M.; Marquès, J. L.; Schein, J.

2014-11-01

In this work a Thomson scattering diagnostic technique was applied to obtain time resolved electron temperature and density values during a gas metal arc welding (GMAW) process. The investigated GMAW process was run with aluminum wire (AlMg 4,5 Mn) with 1.2 mm diameter as a wire electrode, argon as a shielding gas and peak currents in the range of 400 A. Time resolved measurements could be achieved by triggering the laser pulse at shifted time positions with respect to the current pulse driving the process. Time evaluation of resulting electron temperatures and densities is used to investigate the state of the plasma in different phases of the current pulse and to determine the influence of the metal vapor and droplets on the plasma properties.

Structure and Corrosion Behavior of Arc-Sprayed Zn-Al Coatings on Ductile Iron Substrate

NASA Astrophysics Data System (ADS)

Bonabi, Salar Fatoureh; Ashrafizadeh, Fakhreddin; Sanati, Alireza; Nahvi, Saied Mehran

2018-02-01

In this research, four coatings including pure zinc, pure aluminum, a double-layered coating of zinc and aluminum, and a coating produced by simultaneous deposition of zinc and aluminum were deposited on a cast iron substrate using electric arc-spraying technique. The coatings were characterized by XRD, SEM and EDS map and spot analyses. Adhesion strength of the coatings was evaluated by three-point bending tests, where double-layered coating indicated the lowest bending angle among the specimens, with detection of cracks at the coating-substrate interface. Coatings produced by simultaneous deposition of zinc and aluminum possessed a relatively uniform distribution of both metals. In order to evaluate the corrosion behavior of the coatings, cyclic polarization and salt spray tests were conducted. Accordingly, pure aluminum coating showed susceptibility to pitting corrosion and other coatings underwent uniform corrosion. For double-layered coating, SEM micrographs revealed zinc corrosion products as flaky particles in the pores formed by pitting on the surface, an indication of penetration of corrosion products from the lower layer (zinc) to the top layer (aluminum). All coatings experienced higher negative corrosion potentials than the iron substrate, indicative of their sacrificial behavior.

Ultra-high efficiency moving wire combustion interface for on-line coupling of HPLC

PubMed Central

Thomas, Avi T.; Ognibene, Ted; Daley, Paul; Turteltaub, Ken; Radousky, Harry; Bench, Graham

2011-01-01

We describe a 100% efficient moving-wire interface for on-line coupling of high performance liquid chromatography which transmits 100% of carbon in non-volatile analytes to a CO2 gas accepting ion source. This interface accepts a flow of analyte in solvent, evaporates the solvent, combusts the remaining analyte, and directs the combustion products to the instrument of choice. Effluent is transferred to a periodically indented wire by a coherent jet to increase efficiency and maintain peak resolution. The combustion oven is plumbed such that gaseous combustion products are completely directed to an exit capillary, avoiding the loss of combustion products to the atmosphere. This system achieves the near complete transfer of analyte at HPLC flow rates up to 125 μL/min at a wire speed of 6 cm/s. This represents a 30x efficiency increase and 8x maximum wire loading compared to the spray transfer technique used in earlier moving wire interfaces. PMID:22004428

A study of processing parameters in thermal-sprayed alumina and zircon mixtures

NASA Astrophysics Data System (ADS)

Li, Y.; Khor, K. A.

2002-06-01

A method of plasma spraying of alumina and zircon mixtures to form ZrO2-mullite composites has been proposed and developed. The feedstock is prepared by a combination of mechanical alloying, which allows formation of fine-grained, homogeneous solid-solution mixtures, followed by plasma spheroidization that yields rapid solidified microstructures and enhanced compositional homogeneity. The effects of ball-milling duration and milling media were studied. It was found that zirconia is a more efficient milling media and that increasing milling duration enhanced the dissociation of zircon. Flame spray and plasma spray processes were used to spheroidize the spray-dried powders. The temperature of the flame spray was found to be insufficient to melt the powders completely. The processing parameters of the plasma spray played an important role in zircon decomposition and mullite formation. Increasing the arc current or reducing secondary gas pressure caused more zircon to decompose and more mullite to form after heat treatment at 1200 °C for 3 h. Dissociation of zircon and the amount of mullite for med can be enhanced significantly when using the more efficient, computerized plasma-spraying system and increasing the ball-milling duration from 4 to 8 h.

SPRAYTRAN 1.0 User’s Guide: A GIS-Based Atmospheric Spray Droplet Dispersion Modeling System

DOE Office of Scientific and Technical Information (OSTI.GOV)

Allwine, K Jerry; Rutz, Frederick C.; Droppo, James G.

SPRAY TRANsport (SPRAYTRAN) is a comprehensive dispersion modeling system that is used to simulate the offsite drift of pesticides from spray applications. SPRAYTRAN functions as a console application within Environmental System Research Institute’s ArcMap Geographic Information System (Version 9.x) and integrates the widely-used, U.S. Environmental Protection Agency (EPA)-approved CALifornia PUFF (CALPUFF) dispersion model and model components to simulate longer-range transport and diffusion in variable terrain and spatially/temporally varying meteorological (e.g., wind) fields. Area sources, which are used to define spray blocks in SPRAYTRAN, are initialized using output files generated from a separate aerial-spray-application model called AGDISP (AGricultural DISPersal). The AGDISPmore » model is used for estimating the amount of pesticide deposited to the spray block based on spraying characteristics (e.g., pesticide type, spray nozzles, and aircraft type) and then simulating the near-field (less than 300-m) drift from a single pesticide application. The fraction of pesticide remaining airborne from the AGDISP near-field simulation is then used by SPRAYTRAN for simulating longer-range (greater than 300 m) drift and deposition of the pesticide.« less

An experimental study on the thermal characteristics and heating effect of arc-fault from Cu core in residential electrical wiring fires

PubMed Central

Du, Jian-Hua; Zeng, Yi; Pan, Leng; Zhang, Ren-Cheng

2017-01-01

The characteristics of a series direct current (DC) arc-fault including both electrical and thermal parameters were investigated based on an arc-fault simulator to provide references for multi-parameter electrical fire detection method. Tests on arc fault behavior with three different initial circuit voltages, resistances and arc gaps were conducted, respectively. The influences of circuit conditions on arc dynamic image, voltage, current or power were interpreted. Also, the temperature rises of electrode surface and ambient air were studied. The results showed that, first, significant variations of arc structure and light emitting were observed under different conditions. A thin outer burning layer of vapor generated from electrodes with orange light was found due to the extremely high arc temperature. Second, with the increasing electrode gap in discharging, the arc power was shown to have a non monotonic relationship with arc length for constant initial circuit voltage and resistance. Finally, the temperature rises of electrode surface caused by heat transfer from arc were found to be not sensitive with increasing arc length due to special heat transfer mechanism. In addition, temperature of ambient air showed a large gradient in radial direction of arc. PMID:28797055

An experimental study on the thermal characteristics and heating effect of arc-fault from Cu core in residential electrical wiring fires.

PubMed

Du, Jian-Hua; Tu, Ran; Zeng, Yi; Pan, Leng; Zhang, Ren-Cheng

2017-01-01

The characteristics of a series direct current (DC) arc-fault including both electrical and thermal parameters were investigated based on an arc-fault simulator to provide references for multi-parameter electrical fire detection method. Tests on arc fault behavior with three different initial circuit voltages, resistances and arc gaps were conducted, respectively. The influences of circuit conditions on arc dynamic image, voltage, current or power were interpreted. Also, the temperature rises of electrode surface and ambient air were studied. The results showed that, first, significant variations of arc structure and light emitting were observed under different conditions. A thin outer burning layer of vapor generated from electrodes with orange light was found due to the extremely high arc temperature. Second, with the increasing electrode gap in discharging, the arc power was shown to have a non monotonic relationship with arc length for constant initial circuit voltage and resistance. Finally, the temperature rises of electrode surface caused by heat transfer from arc were found to be not sensitive with increasing arc length due to special heat transfer mechanism. In addition, temperature of ambient air showed a large gradient in radial direction of arc.

Method of preparing composite superconducting wire

DOEpatents

Verhoeven, John D.; Gibson, Edwin D.; Finnemore, Douglas K.; Ostenson, Jerome E.; Schmidt, Frederick A.; Owen, Charles V.

1985-08-06

An improved method of preparing composite multifilament superconducting wire of Nb.sub.3 Sn in a copper matrix which eliminates the necessity of coating the drawn wire with tin. A generalized cylindrical billet of an alloy of copper containing at least 15 weight percent niobium, present in the copper as discrete, randomly distributed and oriented dendritic-shaped particles, is provided with at least one longitudinal opening which is filled with tin to form a composite drawing rod. The drawing rod is then drawn to form a ductile composite multifilament wire containing a filament of tin. The ductile wire containing the tin can then be wound into magnet coils or other devices before heating to diffuse the tin through the wire to react with the niobium forming Nb.sub.3 Sn. Also described is an improved method for making large billets of the copper-niobium alloy by consumable-arc casting.

Improved method of preparing composite superconducting wire

DOEpatents

Verhoeven, J.D.; Gibson, E.D.; Finnemore, D.K.; Ostenson, J.E.; Schmidt, F.A.; Owen, C.V.

1979-10-17

An improved method of preparing composite multifilament superconducting wire of Nb/sub 3/Sn in a copper matrix eliminates the necessity of coating the drawn wire with tin. A generalized cylindrical billet of an alloy of copper containing at least 15 weight percent niobium, present in the copper as discrete, randomly distributed and oriented dendritic-shaped particles, is provided with at least one longitudinal opening which is filled with tin to form a composite drawing rod. The drawing rod is then drawn to form a ductile composite multifilament wire containing a filament of tin. The ductile wire containing the tin can then be wound into magnet coils or other devices before heating to diffuse the tin through the wire to react with the niobium forming Nb/sub 3/Sn. Also described is an improved method for making large billets of the copper-niobium alloy by consumable-arc casting.

Fabricating Superior NiAl Bronze Components through Wire Arc Additive Manufacturing.

PubMed

Ding, Donghong; Pan, Zengxi; van Duin, Stephen; Li, Huijun; Shen, Chen

2016-08-03

Cast nickel aluminum bronze (NAB) alloy is widely used for large engineering components in marine applications due to its excellent mechanical properties and corrosion resistance. Casting porosity, as well as coarse microstructure, however, are accompanied by a decrease in mechanical properties of cast NAB components. Although heat treatment, friction stir processing, and fusion welding were implemented to eliminate porosity, improve mechanical properties, and refine the microstructure of as-cast metal, their applications are limited to either surface modification or component repair. Instead of traditional casting techniques, this study focuses on developing NAB components using recently expanded wire arc additive manufacturing (WAAM). Consumable welding wire is melted and deposited layer-by-layer on substrates producing near-net shaped NAB components. Additively-manufactured NAB components without post-processing are fully dense, and exhibit fine microstructure, as well as comparable mechanical properties, to as-cast NAB alloy. The effects of heat input from the welding process and post-weld-heat-treatment (PWHT) are shown to give uniform NAB alloys with superior mechanical properties revealing potential marine applications of the WAAM technique in NAB production.

Fabricating Superior NiAl Bronze Components through Wire Arc Additive Manufacturing

PubMed Central

Ding, Donghong; Pan, Zengxi; van Duin, Stephen; Li, Huijun; Shen, Chen

2016-01-01

Cast nickel aluminum bronze (NAB) alloy is widely used for large engineering components in marine applications due to its excellent mechanical properties and corrosion resistance. Casting porosity, as well as coarse microstructure, however, are accompanied by a decrease in mechanical properties of cast NAB components. Although heat treatment, friction stir processing, and fusion welding were implemented to eliminate porosity, improve mechanical properties, and refine the microstructure of as-cast metal, their applications are limited to either surface modification or component repair. Instead of traditional casting techniques, this study focuses on developing NAB components using recently expanded wire arc additive manufacturing (WAAM). Consumable welding wire is melted and deposited layer-by-layer on substrates producing near-net shaped NAB components. Additively-manufactured NAB components without post-processing are fully dense, and exhibit fine microstructure, as well as comparable mechanical properties, to as-cast NAB alloy. The effects of heat input from the welding process and post-weld-heat-treatment (PWHT) are shown to give uniform NAB alloys with superior mechanical properties revealing potential marine applications of the WAAM technique in NAB production. PMID:28773774

Generator of the low-temperature heterogeneous plasma flow

NASA Astrophysics Data System (ADS)

Yusupov, D. I.; Gadzhiev, M. Kh; Tyuftyaev, A. S.; Chinnov, V. F.; Sargsyan, M. A.

2018-01-01

A generator of low-temperature dc plasma with an expanding channel of an output electrode for gas-thermal spraying was designed and constructed. The delivery of the sprayed powder into the cathode and anode arc-binding zones or into the plasma jet below the anode binding was realized. The electrophysical characteristics of both the plasma torch and the heterogeneous plasma flow with Al2O3 powder are studied. It is shown that the current-voltage characteristic (CVC) of a plasma torch depends on the gas flow rate. If the flow rate varies from 1 to 3 g/s, the falling CVC becomes gradually increasing. The speed and temperature of the sprayed powder are determined.

Cassini UVIS Auroral Observations in 2016 and 2017

NASA Astrophysics Data System (ADS)

Pryor, Wayne R.; Esposito, Larry W.; Jouchoux, Alain; Radioti, Aikaterini; Grodent, Denis; Gustin, Jacques; Gerard, Jean-Claude; Lamy, Laurent; Badman, Sarah; Dyudina, Ulyana A.; Cassini UVIS Team, Cassini VIMS Team, Cassini ISS Team, HST Saturn Auroral Team

2017-10-01

In 2016 and 2017, the Cassini Saturn orbiter executed a final series of high-inclination, low-periapsis orbits ideal for studies of Saturn's polar regions. The Cassini Ultraviolet Imaging Spectrograph (UVIS) obtained an extensive set of auroral images, some at the highest spatial resolution obtained during Cassini's long orbital mission (2004-2017). In some cases, two or three spacecraft slews at right angles to the long slit of the spectrograph were required to cover the entire auroral region to form auroral images. We will present selected images from this set showing narrow arcs of emission, more diffuse auroral emissions, multiple auroral arcs in a single image, discrete spots of emission, small scale vortices, large-scale spiral forms, and parallel linear features that appear to cross in places like twisted wires. Some shorter features are transverse to the main auroral arcs, like barbs on a wire. UVIS observations were in some cases simultaneous with auroral observations from the Cassini Imaging Science Subsystem (ISS) the Cassini Visual and Infrared Mapping Spectrometer (VIMS), and the Hubble Space Telescope Space Telescope Imaging Spectrograph (STIS) that will also be presented.

Projection par plasma de depots de dioxyde de titane: Contribution a l'etude de leurs microstructures et proprietes electriques

NASA Astrophysics Data System (ADS)

Branland, Nadege

2002-04-01

The aim of this PhD work is, thanks to particle parameters (velocity and temperature) characterization, to try to understand the influence of plasma spray parameters on titania coating microstructures and the influence of the latter one on their electrical resistivity, for the same substrate conditions. The experimental approach has consisted in using two plasma spraying processes (Arc plasma spraying and Inductive plasma spraying) which have permitted to obtain a broad range of particle velocities and temperatures leading to coatings with specific microstructures. Despite the stoichiometry of the starting powder, all coatings obtained were grey, the oxygen loss increasing with the particle temperature. Isolating the stoichiometry influence has permitted to show that the decrease of the coatings electrical resistivity is especially due to the decrease of the number of bad interlamellar contacts.

Comparative characteristic and erosion behavior of NiCr coatings deposited by various high-velocity oxyfuel spray processes

NASA Astrophysics Data System (ADS)

Sidhu, Hazoor Singh; Sidhu, Buta Singh; Prakash, S.

2006-12-01

The purpose of this study is to analyze and compare the mechanical properties and microstructure details at the interface of high-velocity oxyfuel (HVOF)-sprayed NiCr-coated boiler tube steels, namely ASTM-SA-210 grade A1, ASTM-SA213-T-11, and ASTM-SA213-T-22. Coatings were developed by two different techniques, and in these techniques liquefied petroleum gas was used as the fuel gas. First, the coatings were characterized by metallographic, scanning electron microscopy/energy-dispersive x-ray analysis, x-ray diffraction, surface roughness, and microhardness, and then were subjected to erosion testing. An attempt has been made to describe the transformations taking place during thermal spraying. It is concluded that the HVOF wire spraying process offers a technically viable and cost-effective alternative to HVOF powder spraying process for applications in an energy generation power plant with a point view of life enhancement and to minimize the tube failures because it gives a coating having better resistance to erosion.

Stress corrosion evaluation of HP 9Ni-4Co-0.30C steel plate welds

NASA Technical Reports Server (NTRS)

Torres, Pablo D.

1993-01-01

A stress corrosion cracking (SCC) investigation was conducted on HP 9Ni-4Co-0.30C steel plate welds (welded by using straight polarity plasma arc and HP 9Ni-4Co-0.20C weld wire) since this material is being considered for use in the Advanced Solid Rocket Motor (ASRM) program. Prior to the welding, the material was double tempered at 538 C (1,000 F). After welding, only part of the material was stress relieved at 510 C (950 F) for 3 h. Round tensile specimens obtained from nonstress-relieved material were tested in 100-percent relative humidity at 38 C (100 F), in 3.5-percent NaCl alternate immersion, and in 5-percent salt spray at 35 C (95 F). Specimens obtained from stress-relieved material were tested in alternate immersion. The stress levels were 50, 75, and 90 percent of the corresponding 0.2-percent yield strength (YS). All the nonstress-relieved specimens exposed to salt spray and alternate immersion failed. Stress-relieved specimens (exposed to alternate immersion) failed at 75 and 90 percent of YS. No failures occurred at 50 percent of YS in the stress-relieved specimens which indicates a beneficial effect of the stress relief on the SCC resistance of these welds. The stress relief also had a positive effect on the mechanical properties of the welds (the most important being an increase of 21 percent on the YS). Under the conditions of these tests, the straight polarity plasma are welded HP 9Ni4Co-0.30C steel plate was found highly susceptible to SCC in the nonstress-relieved condition. This susceptibility to SCC was reduced by stress relieving.

78 FR 21218 - Disclosure of Consumer Complaint Data

Federal Register 2010, 2011, 2012, 2013, 2014

2013-04-10

... customer service and alleviate problems up front by helping consumers avoid ``bad actors.'' They further... Wire Jan. 31, 2013, available at http://www.businesswire.com/news/home/20130131006068/en/Arc-Analyzes...

Optical Emission Studies of the NRL Plasma Torch for the Shipboard Waste Treatment Program

DTIC Science & Technology

1999-02-26

Arc Heating of Molten Steel in a Tundish", Plasma Chemistry and Plasma Processing, Vol.14, pp.361-381,1994. [3] H. Herman, "Plasma-sprayed...Treatment", Plasma Chemistry and Plasma Processing, Vol.15, pp.677-692,1995. [5] S. Paik and H.D. Nguyen, "Numerical Modeling of Multiphase Plasma/Soil Row...Gleizes, S. Vacquie and P. Brunelot, "Modeling of the Cathode Jet of a High- Power Transferred Arc", Plasma Chemistry and Plasma Processing, Vol.13

Kapton wire concerns for aerospace vehicles

NASA Technical Reports Server (NTRS)

Vanlaak, J.

1994-01-01

This presentation outlines the background to the concern of using Kapton wire for aerospace vehicles and proposes it should not be utilized in new builds for spacecraft power applications. A NASA HQ investigation concluded that the risk of Kapton arc-tracking/flashover is a credible threat to the shuttle orbiter, but rationale is presented for continued flight for the time being. Recommendations for the protection of the shuttle and the build of the space station are given.

Structure and Distribution of Components in the Working Layer Upon Reconditioning of Parts by Electric-Arc Metallization

NASA Astrophysics Data System (ADS)

Skoblo, T. S.; Vlasovets, V. M.; Moroz, V. V.

2001-11-01

Reliable data on the structure of the deposited layer are very important due to the considerable instability of the process of deposition of coatings by the method of electric-arc metallization and the strict requirements for reconditioned crankshafts. The present paper is devoted to the structure of coatings obtained from powder wire based on ferrochrome-aluminum with additional alloying elements introduced into the charge.

Performance of Zinc Anodes for Cathodic Protection of Reinforced Concrete Bridges

DOT National Transportation Integrated Search

2002-03-01

Operation of thermal spray zinc (Zn) anodes for cathodic protection (CP) of reinforced concrete structures was investigated in laboratory and field studies conducted by the Albany Research Center (ARC) in collaboration with the Oregon Department of T...

Zinc thermal spray coatings for reinforced concrete: An AWS process standard

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sulit, R.A.

Zinc and aluminum thermal spray coatings (TSC) have been used for lining concrete weir in Great Britain since the 1950`s to maintain the dimensions of the weir for flow control concomitant with reduced wear and erosion of the concrete surfaces. This paper reports the development and the content of the ANSI/AWS C2.20-XX standard for the application of An TSC on concrete using flame and arc spray processes. This standard is formatted as an industrial process instruction: job description; safety; feedstock materials; equipment; a step-by-step method for surface preparation, thermal spraying; quality control; repair and maintenance of surface preparation, thermal spraying;more » quality control; repair and maintenance of Zn TSC on concrete; and a Job Control Record. Job planning and training and certification requirements are presented for An TSC inspectors and thermal spray operators. Four annexes are included in the standard: (a) historical summary of Zn TSC on concrete (b) sample job control record; (c) thermal spray operator qualification; and (d) portable adhesion testing for An TSC on concrete. This standard is based on the current literature and industrial equipment, process, and practices.« less

Method for defect free keyhole plasma arc welding

NASA Technical Reports Server (NTRS)

Harwig, Dennis D. (Inventor); Hunt, James F. (Inventor); Ryan, Patrick M. (Inventor); Fisher, Walter J. (Inventor)

1993-01-01

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.

The dynamic effects of metal vapour in gas metal arc welding

NASA Astrophysics Data System (ADS)

Haidar, Jawad

2010-04-01

Numerical simulations for the dynamic effects of metal vapour in gas metal arc welding (GMAW) suggest that vapour from the welding droplet at the tip of the welding wire has a significant influence on the plasma properties. It is found that for the evaporation rates calculated for arcs in pure argon, the dynamic effects of metal vapour markedly cool down the plasma in the central region of the arc, leading to the formation of a low temperature zone centred on the arc axis, in agreement with experimental measurements in the literature. Radiation effects, omitted in this paper, may produce further cooling of the plasma gas. The results highlight major deficiencies in the common approach to modelling the GMAW process and suggest that accurate description of GMAW must include the influence of metal vapour on the plasma.

Guidelines in the Choice of Parameters for Hybrid Laser Arc Welding with Fiber Lasers

NASA Astrophysics Data System (ADS)

Eriksson, I.; Powell, J.; Kaplan, A.

Laser arc hybrid welding has been a promising technology for three decades and laser welding in combination with gas metal arc welding (GMAW) has shown that it is an extremely promising technique. On the other hand the process is often considered complicated and difficult to set up correctly. An important factor in setting up the hybrid welding process is an understanding of the GMAW process. It is especially important to understand how the wire feed rate and the arc voltage (the two main parameters) affect the process. In this paper the authors show that laser hybrid welding with a 1 μm laser is similar to ordinary GMAW, and several guidelines are therefore inherited by the laser hybrid process.

Collaborative Research and Development (CR&D). Delivery Order 0014: Anti-Fretting Coatings Research Development

DTIC Science & Technology

2006-12-01

properties Deposition Cu / Al in At% Roughness Ra (µm) Nano Hardness (GPa) Modulus (GPa) Thickness (µm) 1 Plasma ≈ 6 ≈ 12 ≈ 1.8 ≈ 89.6 ≈ 300 2... sprayed coatings of different copper to aluminum ( Cu / Al ) ratios and one cathodic arc coating. Bench level gross slip fretting experiments and post...some of Ti6Al4V disks were commercially grit blasted and then plasma sprayed with Al -bronze coatings 1 and 2, which have different Cu / Al

ESTEC wiring test programme materials related properties

NASA Technical Reports Server (NTRS)

Judd, M. D.

1994-01-01

Electrical wires are considered as EEE parts and are covered within the ESA SCC specification series (ESA SCC 3901/XXX). This specification defines the principal properties of the wires including insulation/lay-up and electrical properties. Some additional space related materials requirements are also included, requirements such as outgassing and silver plating thickness. If a project has additional materials requirements over and above those covered by the relevant SCC specification, then additional testing is required. This is especially true for crewed spacecraft. The following topics are discussed in this context: additional requirements for manned spacecraft; flammability; arc tracking; thermal decomposition; microbial surface growth; and ageing.

Analysis of plasma characteristics and conductive mechanism of laser assisted pulsed arc welding

NASA Astrophysics Data System (ADS)

Liu, Shuangyu; Chen, Shixian; Wang, Qinghua; Li, Yanqing; Zhang, Hong; Ding, Hongtao

2017-05-01

This study aims to investigate the arc plasma shape and the spectral characteristics during the laser assisted pulsed arc welding process. The arc plasma shape was synchronously observed using a high speed camera, and the emission spectrum of plasma was obtained by spectrometer. The well-known Boltzmann plot method and Stark broadening were used to calculate the electron temperature and density respectively. The conductive mechanism of arc ignition in laser assisted arc hybrid welding was investigated, and it was found that the plasma current moved to the arc anode under the action of electric field. Thus, a significant parabolic channel was formed between the keyhole and the wire tip. This channel became the main method of energy transformation between the arc and the molten pool. The calculation results of plasma resistivity show that the laser plasma has low resistivity as the starting point of conductive channel formation. When the laser pulse duration increases, the intensity of the plasma radiation spectrum and the plasma electron density will increase, and the electron temperature will decrease.

Protection of Reinforced Concrete Structures of Waste Water Treatment Reservoirs with Stainless Steel Coating Using Arc Thermal Spraying Technique in Acidified Water

PubMed Central

Lee, Han-Seung; Park, Jin-Ho; Singh, Jitendra Kumar; Ismail, Mohamed A.

2016-01-01

Waste water treatment reservoirs are contaminated with many hazardous chemicals and acids. Reservoirs typically comprise concrete and reinforcement steel bars, and the main elements responsible for their deterioration are hazardous chemicals, acids, and ozone. Currently, a variety of techniques are being used to protect reservoirs from exposure to these elements. The most widely used techniques are stainless steel plating and polymeric coating. In this study, a technique known as arc thermal spraying was used. It is a more convenient and economical method for protecting both concrete and reinforcement steel bar from deterioration in waste water treatment reservoirs. In this study, 316L stainless steel coating was applied to a concrete surface, and different electrochemical experiments were performed to evaluate the performance of coatings in different acidic pH solutions. The coating generated from the arc thermal spraying process significantly protected the concrete surface from corrosion in acidic pH solutions, owing to the formation of a double layer capacitance—a mixture of Cr3+ enriched with Cr2O3 and Cr-hydroxide in inner and Fe3+ oxide on the outer layer of the coating. The formation of this passive film is defective owing to the non-homogeneous 316L stainless steel coating surface. In the pH 5 solution, the growth of a passive film is adequate due to the presence of un-dissociated water molecules in the aqueous sulfuric acid solution. The coated surface is sealed with alkyl epoxide, which acts as a barrier against the penetration of acidic solutions. This coating exhibits higher impedance values among the three studied acidic pH solutions. PMID:28773875

Surface microstructure and high temperature corrosion resistance of arc-sprayed FeCrAl coating irradiated by high current pulsed electron beam

NASA Astrophysics Data System (ADS)

Hao, Shengzhi; Zhao, Limin; He, Dongyun

2013-10-01

The surface microstructure of arc-sprayed FeCrAl coating irradiated by high current pulsed electron beam (HCPEB) with long pulse duration of 200 μs was characterized by using optical microscopy, scanning electron microscopy and X-ray diffractometry. The distribution of chemical composition in modified surface layer was measured with electron probe micro-analyzer. The high temperature corrosion resistance of FeCrAl coating was tested in a saturated Na2SO4 and K2SO4 solution at 650 °C. After HCPEB irradiation, the coarse surface of arc-sprayed coating was changed as discrete bulged nodules with smooth and compact appearance. When using low energy density of 20 J/cm2, the surface modified layer was continuous entirely with an average melting depth of ˜30 μm. In the surface remelted layer, Fe and Cr elements gave a uniform distribution, while Al and O elements agglomerated particularly at the concave part between nodule structures to form α-Al2O3 phase. After high temperature corrosion tests, the FeCrAl coating treated with HCPEB of 20 J/cm2 remained a glossy surface with weight increment of ˜51 mg/cm2, decreased by 20% as compared to the initial sample. With the increasing energy density of HCPEB irradiation, the integrity of surface modified layer got segmented due to the formation of larger bulged nodules and cracks at the concave parts. For the HCPEB irradiation of 40 J/cm2, the high temperature corrosion resistance of FeCrAl coating was deteriorated drastically.

Protection of Reinforced Concrete Structures of Waste Water Treatment Reservoirs with Stainless Steel Coating Using Arc Thermal Spraying Technique in Acidified Water.

PubMed

Lee, Han-Seung; Park, Jin-Ho; Singh, Jitendra Kumar; Ismail, Mohamed A

2016-09-03

Waste water treatment reservoirs are contaminated with many hazardous chemicals and acids. Reservoirs typically comprise concrete and reinforcement steel bars, and the main elements responsible for their deterioration are hazardous chemicals, acids, and ozone. Currently, a variety of techniques are being used to protect reservoirs from exposure to these elements. The most widely used techniques are stainless steel plating and polymeric coating. In this study, a technique known as arc thermal spraying was used. It is a more convenient and economical method for protecting both concrete and reinforcement steel bar from deterioration in waste water treatment reservoirs. In this study, 316L stainless steel coating was applied to a concrete surface, and different electrochemical experiments were performed to evaluate the performance of coatings in different acidic pH solutions. The coating generated from the arc thermal spraying process significantly protected the concrete surface from corrosion in acidic pH solutions, owing to the formation of a double layer capacitance-a mixture of Cr 3+ enriched with Cr₂O₃ and Cr-hydroxide in inner and Fe 3+ oxide on the outer layer of the coating. The formation of this passive film is defective owing to the non-homogeneous 316L stainless steel coating surface. In the pH 5 solution, the growth of a passive film is adequate due to the presence of un-dissociated water molecules in the aqueous sulfuric acid solution. The coated surface is sealed with alkyl epoxide, which acts as a barrier against the penetration of acidic solutions. This coating exhibits higher impedance values among the three studied acidic pH solutions.

Performance of Partially Fluorinated Polyimide Insulation for Aerospace Applications

NASA Technical Reports Server (NTRS)

Hammoud, Ahmad N.; Stavnes, Mark W.; Ide, James R.; Muegge, ED

1995-01-01

Polyimide has been used extensively as the primary wiring insulation in commercial planes, military aircraft, and space vehicles due to its low weight, high service temperature, and good dielectric strength. New failure modes, however, have been associated with the use of polyimide because of the susceptibility of the insulation to pyrolization and arc tracking. A new wiring construction utilizing partially fluorinated polyimide insulation has been tested and compared with the standard military polyimide wire. Electrical properties which were investigated include AC corona inception and extinction voltages (sea level and 60,000 feet), time/current to smoke, and wire fusing time. The two constructions were also characterized in terms of their mechanical properties including abrasion resistance, dynamic cut through, and notch propagation. These test efforts and the results obtained are presented and discussed.

Performance of partially fluorinated polyimide insulation for aerospace applications

NASA Astrophysics Data System (ADS)

Hammoud, Ahmad N.; Stavnes, Mark W.; Ide, James R.; Muegge, Ed

1995-08-01

Polyimide has been used extensively as the primary wiring insulation in commercial planes, military aircraft, and space vehicles due to its low weight, high service temperature, and good dielectric strength. New failure modes, however, have been associated with the use of polyimide because of the susceptibility of the insulation to pyrolization and arc tracking. A new wiring construction utilizing partially fluorinated polyimide insulation has been tested and compared with the standard military polyimide wire. Electrical properties which were investigated include AC corona inception and extinction voltages (sea level and 60,000 feet), time/current to smoke, and wire fusing time. The two constructions were also characterized in terms of their mechanical properties including abrasion resistance, dynamic cut through, and notch propagation. These test efforts and the results obtained are presented and discussed.

ARC-1995-AC95-0368-3

NASA Image and Video Library

1995-10-27

Dr Murial Ross's Virtual Reality Application for Neuroscience Research Biocomputation. To study human disorders of balance and space motion sickness. Shown here is a 3D reconstruction of a nerve ending in inner ear, nature's wiring of balance organs.

Structure and properties of Hardox 450 steel with arc welded coatings

NASA Astrophysics Data System (ADS)

Ivanov, Yu. F.; Konovalov, S. V.; Kormyshev, V. E.; Gromov, V. E.; Teresov, A. D.; Semina, O. A.

2017-12-01

The paper reports on a study of the surface structure, phase composition, and microhardness of Hardox 450 steel with coatings deposited by arc welding of powder wires differing in chemical composition. The study shows that to a depth of 6-8 mm, the microhardness of the thus formed coatings is more than two times the microhardness of the base metal and that their higher mechanical properties are provided by martensite structure containing Nb2C and NbC carbides and Fe2B borides as eutectic lamellae with a transverse size of 30-70 nm; their volume reveals a net-like dislocation substructure with a scalar dislocation density of 1011 cm-2. The highest surface hardness is found for the steel coated with boron-containing wire material. Some ideas are suggested on possible mechanisms and temperature for the formation of Nb and B carbides during the process.

A 36,000-Year-Old Volcanic Eruption Depicted in the Chauvet-Pont d’Arc Cave (Ardèche, France)?

PubMed Central

Nomade, Sébastien; Genty, Dominique; Sasco, Romain; Scao, Vincent; Féruglio, Valérie; Baffier, Dominique; Guillou, Hervé; Bourdier, Camille; Valladas, Hélène; Reigner, Edouard; Debard, Evelyne; Pastre, Jean–François; Geneste, Jean-Michel

2016-01-01

Among the paintings and engravings found in the Chauvet-Pont d’Arc cave (Ardèche, France), several peculiar spray-shape signs have been previously described in the Megaloceros Gallery. Here we document the occurrence of strombolian volcanic activity located 35 km northwest of the cave, and visible from the hills above the cave entrance. The volcanic eruptions were dated, using 40Ar/39Ar, between 29 ± 10 ka and 35 ± 8 ka (2σ), which overlaps with the 14C AMS and thermoluminescence ages of the first Aurignacian occupations of the cave in the Megaloceros Gallery. Our work provides the first evidence of an intense volcanic activity between 40 and 30 ka in the Bas-Vivarais region, and it is very likely that Humans living in the Ardèche river area witnessed one or several eruptions. We propose that the spray-shape signs found in the Chauvet-Pont d’Arc cave could be the oldest known depiction of a volcanic eruption, predating by more than 34 ka the description by Pliny the Younger of the Vesuvius eruption (AD 79) and by 28 ka the Çatalhöyük mural discovered in central Turkey. PMID:26745626

A 36,000-Year-Old Volcanic Eruption Depicted in the Chauvet-Pont d'Arc Cave (Ardèche, France)?

PubMed

Nomade, Sébastien; Genty, Dominique; Sasco, Romain; Scao, Vincent; Féruglio, Valérie; Baffier, Dominique; Guillou, Hervé; Bourdier, Camille; Valladas, Hélène; Reigner, Edouard; Debard, Evelyne; Pastre, Jean-François; Geneste, Jean-Michel

2016-01-01

Among the paintings and engravings found in the Chauvet-Pont d'Arc cave (Ardèche, France), several peculiar spray-shape signs have been previously described in the Megaloceros Gallery. Here we document the occurrence of strombolian volcanic activity located 35 km northwest of the cave, and visible from the hills above the cave entrance. The volcanic eruptions were dated, using 40Ar/39Ar, between 29 ± 10 ka and 35 ± 8 ka (2σ), which overlaps with the 14C AMS and thermoluminescence ages of the first Aurignacian occupations of the cave in the Megaloceros Gallery. Our work provides the first evidence of an intense volcanic activity between 40 and 30 ka in the Bas-Vivarais region, and it is very likely that Humans living in the Ardèche river area witnessed one or several eruptions. We propose that the spray-shape signs found in the Chauvet-Pont d'Arc cave could be the oldest known depiction of a volcanic eruption, predating by more than 34 ka the description by Pliny the Younger of the Vesuvius eruption (AD 79) and by 28 ka the Çatalhöyük mural discovered in central Turkey.

Validation of NHB 8060.1C, Test 18 Arc Tracking, September 30, 1991

NASA Technical Reports Server (NTRS)

Linley, Larry

2005-01-01

A test project was conducted to validate Test 18 of NASA Handbook (NHB) 8060.1C and, if necessary, identify and recommend improvements in the procedures or criteria of the test. The NHB 8060.1C, Test 18 test system was modified to produce better discrimination of test results. Changes, and their effects on test results, in the graphite immersion-depth, test timing sequence, and atmospheric conditions were investigated for the wire-insulation constructions tested. Based on the test results, the graphite immersion-depths (between 0.8 mm and 1.6 mm), the timing sequence, and the change in the test conditions from ambient to three environments common in manned spaceflight did not significantly affect test results. The criteria used in Test 18 of NHB 8060.1C was found to be appropriate for qualifying arc-tracking and arc-propagation characteristics of wire-insulation materials, Using the Test 18 criteria, Kapton and ETFE were considered inappropriate for use, while PTFE was considered appropriate. Recommendations from this test project for Test 18 of NHB 8060.1C include changing the experimental setup and configurational tests and performing qualification testing in air rather than in the three environments common in manned spaceflight.

Influence of Filler Wire Feed Rate in Laser-Arc Hybrid Welding of T-butt Joint in Shipbuilding Steel with Different Optical Setups

NASA Astrophysics Data System (ADS)

Unt, Anna; Poutiainen, Ilkka; Salminen, Antti

In this paper, a study of laser-arc hybrid welding featuring three different process fibres was conducted to build knowledge about process behaviour and discuss potential benefits for improving the weld properties. The welding parameters affect the weld geometry considerably, as an example the increase in welding speed usually decreases the penetration and a larger beam diameter usually widens the weld. The laser hybrid welding system equipped with process fibres with 200, 300 and 600 μm core diameter were used to produce fillet welds. Shipbuilding steel AH36 plates with 8 mm thickness were welded with Hybrid-Laser-Arc-Welding (HLAW) in inversed T configuration, the effects of the filler wire feed rate and the beam positioning distance from the joint plane were investigated. Based on the metallographic cross-sections, the effect of process parameters on the joint geometry was studied. Joints with optimized properties (full penetration, soundness, smooth transition from bead to base material) were produced with 200 μm and 600 μm process fibres, while fiber with 300 μm core diameter produced welds with unacceptable levels of porosity.

Hybrid Welding of 45 mm High Strength Steel Sections

NASA Astrophysics Data System (ADS)

Bunaziv, Ivan; Frostevarg, Jan; Akselsen, Odd M.; Kaplan, Alexander F.

Thick section welding has significant importance for oil and gas industry in low temperature regions. Arc welding is usually employed providing suitable quality joints with acceptable toughness at low temperatures with very limited productivity compared to modern high power laser systems. Laser-arc hybrid welding (LAHW) can enhance the productivity by several times due to higher penetration depth from laser beam and combined advantages of both heat sources. LAHW was applied to join 45 mm high strength steel with double-sided technique and application of metal cored wire. The process was captured by high speed camera, allowing process observation in order to identify the relation of the process stability on weld imperfections and efficiency. Among the results, it was found that both arc power and presence of a gap increased penetration depth, and that higher welding speeds cause unstable processing and limits penetration depth. Over a wide range of heat inputs, the welds where found to consist of large amounts of fine-grained acicular ferrite in the upper 60-75% part of welds. At the root filler wire mixing was less and cooling faster, and thus found to have bainitic transformation. Toughness of deposited welds provided acceptable toughness at -50 °C with some scattering.

Using of fiber-array diagnostic to measure the propagation of fast axial ionization wave during breakdown of electrically exploding tungsten wire in vacuum.

PubMed

Shi, Huantong; Zou, Xiaobing; Wang, Xinxin

2017-12-01

The physical process of electrical explosion of wires in vacuum is featured with the surface discharge along the wire, which generates the corona plasma layer and terminates the Joule heating of the wire core. In this paper, a fiber-array probe was designed to directly measure the radiation of surface arc with spatial and temporal resolution. The radiation of the exploding wire was casted to the section of an optical-fiber-array by a lens and transmitted to PIN diodes and finally collected with an oscilloscope. This probe enables direct diagnostics of the evolution of surface discharge with high temporal resolution and certain spatial resolution. The radiation of a tungsten wire driven by a positive current pulse was measured, and results showed that surface discharge initiates near the cathode and propagates toward the anode with a speed of 7.7 ± 1.6 mm/ns; further estimations showed that this process is responsible for the "conical" structure of the exploding wire.

Using of fiber-array diagnostic to measure the propagation of fast axial ionization wave during breakdown of electrically exploding tungsten wire in vacuum

NASA Astrophysics Data System (ADS)

Shi, Huantong; Zou, Xiaobing; Wang, Xinxin

2017-12-01

The physical process of electrical explosion of wires in vacuum is featured with the surface discharge along the wire, which generates the corona plasma layer and terminates the Joule heating of the wire core. In this paper, a fiber-array probe was designed to directly measure the radiation of surface arc with spatial and temporal resolution. The radiation of the exploding wire was casted to the section of an optical-fiber-array by a lens and transmitted to PIN diodes and finally collected with an oscilloscope. This probe enables direct diagnostics of the evolution of surface discharge with high temporal resolution and certain spatial resolution. The radiation of a tungsten wire driven by a positive current pulse was measured, and results showed that surface discharge initiates near the cathode and propagates toward the anode with a speed of 7.7 ± 1.6 mm/ns; further estimations showed that this process is responsible for the "conical" structure of the exploding wire.

A bounding-based solution approach for the continuous arc covering problem

NASA Astrophysics Data System (ADS)

Wei, Ran; Murray, Alan T.; Batta, Rajan

2014-04-01

Road segments, telecommunication wiring, water and sewer pipelines, canals and the like are important features of the urban environment. They are often conceived of and represented as network-based arcs. As a result of the usefulness and significance of arc-based features, there is a need to site facilities along arcs to serve demand. Examples of such facilities include surveillance equipment, cellular towers, refueling centers and emergency response stations, with the intent of being economically efficient as well as providing good service along the arcs. While this amounts to a continuous location problem by nature, various discretizations are generally relied upon to solve such problems. The result is potential for representation errors that negatively impact analysis and decision making. This paper develops a solution approach for the continuous arc covering problem that theoretically eliminates representation errors. The developed approach is applied to optimally place acoustic sensors and cellular base stations along a road network. The results demonstrate the effectiveness of this approach for ameliorating any error and uncertainty in the modeling process.

A model for heat and mass input control in GMAW

DOE Office of Scientific and Technical Information (OSTI.GOV)

Smartt, H.B.; Einerson, C.J.

1993-05-01

This work describes derivation of a control model for electrode melting and heat and mass transfer from the electrode to the work piece in gas metal arc welding (GMAW). Specifically, a model is developed which allows electrode speed and welding speed to be calculated for given values of voltage and torch-to-base metal distance, as a function of the desired heat and mass input to the weldment. Heat input is given on a per unit weld length basis, and mass input is given in terms of transverse cross-sectional area added to the weld bead (termed reinforcement). The relationship to prior workmore » is discussed. The model was demonstrated using a computer-controlled welding machine and a proportional-integral (PI) controller receiving input from a digital filter. The difference between model-calculated welding current and measured current is used as controller feedback. The model is calibrated for use with carbon steel welding wire and base plate with Ar-CO[sub 2] shielding gas. Although the system is intended for application during spray transfer of molten metal from the electrode to the weld pool, satisfactory performance is also achieved during globular and streaming transfer. Data are presented showing steady-state and transient performance, as well as resistance to external disturbances.« less

Inquiry with Laser Printer Diffraction Gratings

ERIC Educational Resources Information Center

Van Hook, Stephen J.

2007-01-01

The pages of "The Physics Teacher" have featured several clever designs for homemade diffraction gratings using a variety of materials--cloth, lithographic film, wire, compact discs, parts of aerosol spray cans, and pseudoliquids and pseudosolids. A different and inexpensive method I use to make low-resolution diffraction gratings takes advantage…

Electrocution by arcing: a nonfatal case study.

PubMed

Solarino, Biagio; Di Vella, Giancarlo

2011-12-01

Accidental electrocution during working activities account for a considerable amount of morbidity and mortality. Workers often misjudge the danger of electric wires or high-tension power cables, thereby exposing themselves to electrocution hazard. This article describes a nonfatal case of injuries by arcing from high-tension power-line cables involving a young farmer who was thrashing an olive tree by means of aluminum ladder. The circumstances surrounding the manner of electrocution and the features of electric injuries are presented and discussed.

Orienting Arc Lamps for Longest Life

NASA Technical Reports Server (NTRS)

Kiss, J.

1985-01-01

Temperature distribution strongly affects performance. Tests on floodlights for Space Shuttle payload bay show useful life of metal halide dc arc lamp prolonged by mounting "anode down" and wiring for maximum heat conduction away from electrodes. Anode-down configuration, anode and cathode temperatures stabilize at 333 degrees and 313 degrees C, respectively, after 1 hour of operation. Temperatures both below limit for quartz-to-metal seals, and lamps able to withstand a 2,000-hour life test with satisfactory light output at end.

Profiling mild steel welding processes to reduce fume emissions and costs in the workplace.

PubMed

Keane, Michael J; Siert, Arlen; Chen, Bean T; Stone, Samuel G

2014-05-01

To provide quantitative information to choose the best welding processes for minimizing workplace emissions, nine gas metal arc welding (GMAW) processes for mild steel were assessed for fume generation rates, normalized fume generation rates (milligram fume per gram of electrode consumed), and normalized generation rates for elemental manganese, nickel, and iron. Shielded metal arc welding (SMAW) and flux-cored arc-welding (FCAW) processes were also profiled. The fumes were collected quantitatively in an American Welding Society-type fume chamber and weighed, recovered, homogenized, and analyzed by inductively coupled atomic emission spectroscopy for total metals. The processes included GMAW with short circuit, globular transfer, axial spray, pulsed spray, Surface Tension Transfer™, Regulated Metal Deposition™, and Cold Metal Transfer™ (CMT) modes. Flux-cored welding was gas shielded, and SMAW was a single rod type. Results indicate a wide range of fume emission factors for the process variations studied. Fume emission rates per gram of electrode consumed were highest for SMAW (~13 mg fume g(-1) electrode) and lowest for GMAW processes such as pulsed spray (~1.5mg g(-1)) and CMT (~1mg g(-1)). Manganese emission rates per gram of electrode consumed ranged from 0.45 mg g(-1) (SMAW) to 0.08 mg g(-1) (CMT). Nickel emission rates were generally low and ranged from ~0.09 (GMAW short circuit) to 0.004 mg g(-1) (CMT). Iron emission rates ranged from 3.7 (spray-mode GMAW) to 0.49 mg g(-1) (CMT). The processes studied have significantly different costs, and cost factors are presented based on a case study to allow comparisons between processes in specific cost categories. Costs per linear meter of weld were $31.07 (SMAW), $12.37 (GMAW short circuit), and $10.89 (FCAW). Although no single process is the best for minimizing fume emissions and costs while satisfying the weld requirements, there are several processes that can minimize emissions. This study provides information to aid in those choices. Suggestions for overcoming barriers to utilizing new and less hazardous welding processes are also discussed.

Profiling Mild Steel Welding Processes to Reduce Fume Emissions and Costs in the Workplace

PubMed Central

Keane, Michael J.; Siert, Arlen; Chen, Bean T.; Stone, Samuel G.

2015-01-01

To provide quantitative information to choose the best welding processes for minimizing workplace emissions, nine gas metal arc welding (GMAW) processes for mild steel were assessed for fume generation rates, normalized fume generation rates (milligram fume per gram of electrode consumed), and normalized generation rates for elemental manganese, nickel, and iron. Shielded metal arc welding (SMAW) and flux-cored arc-welding (FCAW) processes were also profiled. The fumes were collected quantitatively in an American Welding Society-type fume chamber and weighed, recovered, homogenized, and analyzed by inductively coupled atomic emission spectroscopy for total metals. The processes included GMAW with short circuit, globular transfer, axial spray, pulsed spray, Surface Tension Transfer™, Regulated Metal Deposition™, and Cold Metal Transfer™ (CMT) modes. Flux-cored welding was gas shielded, and SMAW was a single rod type. Results indicate a wide range of fume emission factors for the process variations studied. Fume emission rates per gram of electrode consumed were highest for SMAW (~13 mg fume g−1 electrode) and lowest for GMAW processes such as pulsed spray (~1.5 mg g−1) and CMT (~1 mg g−1). Manganese emission rates per gram of electrode consumed ranged from 0.45 mg g−1 (SMAW) to 0.08 mg g−1 (CMT). Nickel emission rates were generally low and ranged from ~0.09 (GMAW short circuit) to 0.004 mg g−1 (CMT). Iron emission rates ranged from 3.7 (spray-mode GMAW) to 0.49 mg g−1 (CMT). The processes studied have significantly different costs, and cost factors are presented based on a case study to allow comparisons between processes in specific cost categories. Costs per linear meter of weld were $31.07 (SMAW), $12.37 (GMAW short circuit), and $10.89 (FCAW). Although no single process is the best for minimizing fume emissions and costs while satisfying the weld requirements, there are several processes that can minimize emissions. This study provides information to aid in those choices. Suggestions for overcoming barriers to utilizing new and less hazardous welding processes are also discussed. PMID:24515891

UNIVERSITY OF WASHINGTON ELECTROSTATIC SCRUBBER TESTS AT A STEEL PLANT

EPA Science Inventory

The report gives results of a demonstration of the effectiveness of a 1700 cu m/hr (1000 acfm) University of Washington (UW) Electrostatic Spray Scrubber in controlling fine particle emissions from an electric-arc steel furnace. The two-stage portable pilot plant operates by comb...

Crack-Free, Nondistorting Can For Hot Isostatic Pressing

NASA Technical Reports Server (NTRS)

Juhas, John J.

1991-01-01

New method of canning specimens made of composites of arc-sprayed and plasma-sprayed tape reduces outgassing and warping during hot isostatic pressing. Produces can having reliable, crack-free seal and thereby helps to ensure pressed product of high quality. Specimen placed in ring of refractory metal between two face sheets, also of refractory metal. Assembly placed in die in vacuum hot press, where simultaneously heated and pressed until plates become diffusion-welded to ring, forming sealed can around specimen. Specimen becomes partially densified, and fits snugly within can. Ready for further densification by hot isostatic pressing.

Use of predissociation to enhance the atomic hydrogen ion fraction in ion sources

DOEpatents

Kim, Jinchoon

1979-01-01

A duopigatron ion source is modified by replacing the normal oxide-coated wire filament cathode of the ion source with a hot tungsten oven through which hydrogen gas is fed into the arc chamber. The hydrogen gas is predissociated in the hot oven prior to the arc discharge, and the recombination rate is minimized by hot walls inside of the arc chamber. With the use of the above modifications, the atomic H.sub.1.sup.+ ion fraction output can be increased from the normal 50% to greater than 70% with a corresponding decrease in the H.sub.2.sup.+ and H.sub.3.sup.+ molecular ion fraction outputs from the ion source.

Forming Completely Penetrated Welded T-joints when Pulsed Arc Welding

NASA Astrophysics Data System (ADS)

Krampit, N. Yu; Krampit, M. A.; Sapozhkov, A. S.

2016-04-01

The paper is focused on revealing the influence of welding parameters on weld formation when pulsed arc welding. As an experimental sample a T-joint over 10 mm was selected. Welding was carried out in flat position, which required no edge preparation but provided mono-directional guaranteed root penetration. The following parameters of welding were subjected to investigation: gap in the joint, wire feed rate and incline angles of the torch along and across the weld axis. Technological recommendations have been made with respect to pulsed arc welding; the cost price of product manufacturing can be reduced on their basis due to reduction of labor input required by machining, lowering consumption of welding materials and electric power.

A Novel Approach for High Deposition Rate Cladding with Minimal Dilution with an Arc - Laser Process Combination

NASA Astrophysics Data System (ADS)

Barroi, A.; Hermsdorf, J.; Prank, U.; Kaierle, S.

First results of the process development of a novel approach for a high deposition rate cladding process with minimal dilution are presented. The approach will combine the enormous melting potential of an electrical arc that burns between two consumable wire electrodes with the precision of a laser process. Separate test for the plasma melting and for the laser based surface heating have been performed. A steadily burning arc between the electrodes could be established and a deposition rate of 10 kg/h could be achieved. The laser was able to apply the desired heat profile, needed for the combination of the processes. Process problems were analyzed and solutions proposed.

Substantially oxygen-free contact tube

NASA Technical Reports Server (NTRS)

Pike, James F. (Inventor)

1993-01-01

A device for arc welding is provided in which a continuously-fed electrode wire is in electrical contact with a contact tube. The contact tube is improved by using a substantially oxygen-free conductive alloy in order to reduce the amount of electrical erosion.

Substantially Oxygen-Free Contact Tube

NASA Technical Reports Server (NTRS)

Pike, James F. (Inventor)

1991-01-01

A device for arc welding is provided in which a continuously-fed electrode wire is in electrical contact with a contact tube. The contact tube is improved by using a substantially oxygen-free conductive alloy in order to reduce the amount of electrical erosion.

Study of Traverse Speed Effects on Residual Stress State and Cavitation Erosion Behavior of Arc-Sprayed Aluminum Bronze Coatings

NASA Astrophysics Data System (ADS)

Hauer, Michél; Henkel, Knuth Michael; Krebs, Sebastian; Kroemmer, Werner

2017-01-01

Within a research project regarding cavitation erosion-resistant coatings, arc spraying was used with different traverse speeds to influence heat transfer and the resulting residual stress state. The major reason for this study is the lack of knowledge concerning the influence of residual stress distribution on mechanical properties and coating adhesion, especially with respect to heterogeneous aluminum bronze alloys. The materials used for spray experiments were the highly cavitation erosion-resistant propeller alloys CuAl9Ni5Fe4Mn (Ni-Al-Bronze) and CuMn13Al8Fe3Ni2 (Mn-Al-Bronze). Analyses of cavitation erosion behavior were carried out to evaluate the suitability for use in marine environments. Further microstructural, chemical and mechanical analyses were realized to examine adhesive and cohesive coating properties. Residual stress distribution was measured by modified hole drilling method using electronic speckle pattern interferometry (ESPI). It was found that the highest traverse speed led to higher tensile residual stresses near the surface and less cavitation erosion resistance of the coatings. Moreover, high oxygen affinity of main alloying element aluminum was identified to severely influence the microstructures by the formation of large oxides and hence the coating properties. Overall, Mn-Al-Bronze coatings showed lower residual stresses, a more homogeneous pore and oxide distribution and less material loss by cavitation than Ni-Al-Bronze coatings.

Blast Coating of Superelastic NiTi Wire with PTFE to Enhance Wear Properties

NASA Astrophysics Data System (ADS)

Dunne, Conor F.; Roche, Kevin; Twomey, Barry; Hodgson, Darel; Stanton, Kenneth T.

2015-03-01

This work investigates the deposition of polytetrafluoroethylene (PTFE) onto a superelastic NiTi wire using an ambient temperature-coating technique known as CoBlast. The process utilises a stream of abrasive (Al2O3) and a coating medium (PTFE) sprayed simultaneously at the surface of the substrate. Superelastic NiTi wire is used in guidewire applications, and PTFE coatings are commonly applied to reduce damage to vessel walls during insertion and removal, and to aid in accurate positioning by minimising the force required to advance, retract or rotate the wire. The CoBlast coated wires were compared to wire treated with PTFE only. The coated samples were examined using variety of techniques: X-ray diffraction (XRD), microscopy, surface roughness, wear testing and flexural tests. The CoBlast coated samples had an adherent coating with a significant resistance to wear compared to the samples coated with PTFE only. The XRD revealed that the process gave rise to a stress-induced martensite phase in the NiTi which may enhance mechanical properties. The study indicates that the CoBlast process can be used to deposit thin adherent coatings of PTFE onto the surface of superelastic NiTi.

Fabrication of gas turbine water-cooled composite nozzle and bucket hardware employing plasma spray process

DOEpatents

Schilke, Peter W.; Muth, Myron C.; Schilling, William F.; Rairden, III, John R.

1983-01-01

In the method for fabrication of water-cooled composite nozzle and bucket hardware for high temperature gas turbines, a high thermal conductivity copper alloy is applied, employing a high velocity/low pressure (HV/LP) plasma arc spraying process, to an assembly comprising a structural framework of copper alloy or a nickel-based super alloy, or combination of the two, and overlying cooling tubes. The copper alloy is plamsa sprayed to a coating thickness sufficient to completely cover the cooling tubes, and to allow for machining back of the copper alloy to create a smooth surface having a thickness of from 0.010 inch (0.254 mm) to 0.150 inch (3.18 mm) or more. The layer of copper applied by the plasma spraying has no continuous porosity, and advantageously may readily be employed to sustain a pressure differential during hot isostatic pressing (HIP) bonding of the overall structure to enhance bonding by solid state diffusion between the component parts of the structure.

Laser-TIG Welding of Titanium Alloys

NASA Astrophysics Data System (ADS)

Turichin, G.; Tsibulsky, I.; Somonov, V.; Kuznetsov, M.; Akhmetov, A.

2016-08-01

The article presents the results of investigation the technological opportunity of laser-TIG welding of titanium alloys. The experimental stand for implementation of process with the capability to feed a filler wire was made. The research of the nature of transfer the filler wire into the welding pool has been demonstrated. The influence of distance between the electrode and the surface of the welded plates on the stability of the arc was shown. The relationship between welding velocity, the position of focal plane of the laser beam and the stability of penetration of plates was determined.

Development and analysis of insulation constructions for aerospace wiring applications

NASA Astrophysics Data System (ADS)

Slenski, George A.; Woodford, Lynn M.

1993-03-01

The Wright Laboratory Materials Directorate at WPAFB, Ohio recently completed a research and development program under contract with the McDonnell Douglas Aerospace Company, St. Louis, Missouri. Program objectives were to develop wire insulation performance requirements, evaluate candidate insulations, and prepare preliminary specification sheets on the most promising candidates. Aircraft wiring continues to be a high maintenance item and a major contributor to electrically-related aircraft mishaps. Mishap data on aircraft show that chafing of insulation is the most common mode of wire failure. Improved wiring constructions are expected to increase aircraft performance and decrease costs by reducing maintenance actions. In the laboratory program, new insulation constructions were identified that had overall improved performance in evaluation tests when compared to currently available MIL-W-81381 and MIL-W-22759 wiring. These insulations are principally aromatic polyimide and crosslinked ethylene tetrafluoroethylene (ETFE), respectively. Candidate insulations identified in preliminary specification sheets were principally fluoropolymers with a polyimide inner layer. Examples of insulation properties evaluated included flammability, high temperature mechanical and electrical performance, fluid immersion, and susceptibility to arc propagation under applied power chafing conditions. Potential next generation wire insulation materials are also reviewed.

Comparative range of orthodontic wires.

PubMed

Ingram, S B; Gipe, D P; Smith, R J

1986-10-01

ADA specification No. 32 for determining the range (elastic limit) of orthodontic wires uses the bending of a wire section treated as a cantilever beam. An alternative method for defining the range of orthodontic wires proposed by Waters (1981) is to wrap wire sections around mandrels of varying diameters and measure the deformation imparted after unwrapping. Four brass mandrels with a total of 46 test diameters ranging from 3.5 to 60.0 mm were used in this study. Wire sections 9 cm in length were rolled on the mandrel with a hand lathe. The mandrel cross section required to produce a predetermined amount of deformation (2 mm arc height for a 5 cm chord) was defined as the yield diameter for that particular wire. No individual wire was tested twice so as to avoid introduction of strain history. Test samples of 488 different orthodontic wires supplied by nine commercial distributors were evaluated (a total of 4,747 samples). Stainless steel wires of identical dimensions had a large variation in range, depending on the state of strain hardening and heat treatment. For example, 0.020 inch round wire had yield diameters ranging from 22.8 mm for Australian special plus orange (TP Laboratories) to 42.9 mm for Nubryte gold (G.A.C. International). Chromium cobalt wires had less range than stainless steel before heat treatment, but increased greatly in range after heat treatment. Nitinol (Unitek) had the greatest range of all wires tested (yield diameter of 8.7 mm for 0.016 inch Nitinol). Multistranded stainless steel wires had yield diameters between 9.0 and 14.0 mm.

Cassini UVIS Observations of Saturn during the Grand Finale Orbits

NASA Astrophysics Data System (ADS)

Pryor, W. R.; Esposito, L. W.; West, R. A.; Jouchoux, A.; Radioti, A.; Grodent, D. C.; Gerard, J. C. M. C.; Gustin, J.; Lamy, L.; Badman, S. V.

2017-12-01

In 2016 and 2017, the Cassini Saturn orbiter executed a final series of high inclination, low-periapsis orbits ideal for studies of Saturn's polar regions. The Cassini Ultraviolet Imaging Spectrograph (UVIS) obtained an extensive set of auroral images, some at the highest spatial resolution obtained during Cassini's long orbital mission (2004-2017). In some cases, two or three spacecraft slews at right angles to the long slit of the spectrograph were required to cover the entire auroral region to form auroral images. We will present selected images from this set showing narrow arcs of emission, more diffuse auroral emissions, multiple auroral arcs in a single image, discrete spots of emission, small scale vortices, large-scale spiral forms, and parallel linear features that appear to cross in places like twisted wires. Some shorter features are transverse to the main auroral arcs, like barbs on a wire. UVIS observations were in some cases simultaneous with auroral observations from the Hubble Space Telescope Space Telescope Imaging Spectrograph (STIS) that will also be presented. UVIS polar images also contain spectral information suitable for studies of the auroral electron energy distribution. The long wavelength part of the UVIS polar images contains a signal from reflected sunlight containing absorption signatures of acetylene and other Saturn hydrocarbons. The hydrocarbon spatial distribution will also be examined.

Specifics of Pulsed Arc Welding Power Supply Performance Based On A Transistor Switch

NASA Astrophysics Data System (ADS)

Krampit, N. Yu; Kust, T. S.; Krampit, M. A.

2016-08-01

Specifics of designing a pulsed arc welding power supply device are presented in the paper. Electronic components for managing large current was analyzed. Strengths and shortcomings of power supply circuits based on thyristor, bipolar transistor and MOSFET are outlined. As a base unit for pulsed arc welding was chosen MOSFET transistor, which is easy to manage. Measures to protect a transistor are given. As for the transistor control device is a microcontroller Arduino which has a low cost and adequate performance of the work. Bead transfer principle is to change the voltage on the arc in the formation of beads on the wire end. Microcontroller controls transistor when the arc voltage reaches the threshold voltage. Thus there is a separation and transfer of beads without splashing. Control strategies tested on a real device and presented. The error in the operation of the device is less than 25 us, it can be used controlling drop transfer at high frequencies (up to 1300 Hz).

Real-time monitoring of laser hot-wire cladding of Inconel 625

NASA Astrophysics Data System (ADS)

Liu, Shuang; Liu, Wei; Harooni, Masoud; Ma, Junjie; Kovacevic, Radovan

2014-10-01

Laser hot-wire cladding (LHWC), characterized by resistance heating of the wire, largely increases the productivity and saves the laser energy. However, the main issue of applying this method is the occurrence of arcing which causes spatters and affects the stability of the process. In this study, an optical spectrometer was used for real-time monitoring of the LHWC process. The corresponding plasma intensity was analyzed under various operating conditions. The electron temperature of the plasma was calculated for elements of nickel and chromium that mainly comprised the plasma plume. There was a correlation between the electron temperature and the stability of the process. The characteristics of the resulted clad were also investigated by measuring the dilution, hardness and microstructure.

30 CFR 75.1323 - Blasting circuits.

Code of Federal Regulations, 2010 CFR

2010-07-01

...) Blasting circuits shall be protected from sources of stray electric current. (b) Detonators made by...) Each wire connection in a blasting circuit shall be— (1) Properly spliced; and (2) Separated from other connections in the circuit to prevent accidental contact and arcing. (h) Uninsulated connections in each...

30 CFR 75.1323 - Blasting circuits.

Code of Federal Regulations, 2011 CFR

2011-07-01

...) Blasting circuits shall be protected from sources of stray electric current. (b) Detonators made by...) Each wire connection in a blasting circuit shall be— (1) Properly spliced; and (2) Separated from other connections in the circuit to prevent accidental contact and arcing. (h) Uninsulated connections in each...

Short pulse, high resolution, backlighters for point projection high-energy radiography at the National Ignition Facility

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tommasini, R.; Bailey, C.; Bradley, D. K.

High-resolution, high-energy X-ray backlighters are very active area of research for radiography experiments at the National Ignition Facility (NIF) [Miller et al., Nucl. Fusion 44, S228 (2004)], in particular those aiming at obtaining Compton-scattering produced radiographs from the cold, dense fuel surrounding the hot spot. We report on experiments to generate and characterize point-projection-geometry backlighters using short pulses from the advanced radiographic capability (ARC) [Crane et al., J. Phys. 244, 032003 (2010); Di Nicola et al., Proc. SPIE 2015, 93450I-12], at the NIF, focused on Au micro-wires. We show the first hard X-ray radiographs, at photon energies exceeding 60 keV,more » of static objects obtained with 30 ps-long ARC laser pulses, and the measurements of strength of the X-ray emission, the pulse duration and the source size of the Au micro-wire backlighters. For the latter, a novel technique has been developed and successfully applied.« less

Short pulse, high resolution, backlighters for point projection high-energy radiography at the National Ignition Facility

NASA Astrophysics Data System (ADS)

Tommasini, R.; Bailey, C.; Bradley, D. K.; Bowers, M.; Chen, H.; Di Nicola, J. M.; Di Nicola, P.; Gururangan, G.; Hall, G. N.; Hardy, C. M.; Hargrove, D.; Hermann, M.; Hohenberger, M.; Holder, J. P.; Hsing, W.; Izumi, N.; Kalantar, D.; Khan, S.; Kroll, J.; Landen, O. L.; Lawson, J.; Martinez, D.; Masters, N.; Nafziger, J. R.; Nagel, S. R.; Nikroo, A.; Okui, J.; Palmer, D.; Sigurdsson, R.; Vonhof, S.; Wallace, R. J.; Zobrist, T.

2017-05-01

High-resolution, high-energy X-ray backlighters are very active area of research for radiography experiments at the National Ignition Facility (NIF) [Miller et al., Nucl. Fusion 44, S228 (2004)], in particular those aiming at obtaining Compton-scattering produced radiographs from the cold, dense fuel surrounding the hot spot. We report on experiments to generate and characterize point-projection-geometry backlighters using short pulses from the advanced radiographic capability (ARC) [Crane et al., J. Phys. 244, 032003 (2010); Di Nicola et al., Proc. SPIE 2015, 93450I-12], at the NIF, focused on Au micro-wires. We show the first hard X-ray radiographs, at photon energies exceeding 60 keV, of static objects obtained with 30 ps-long ARC laser pulses, and the measurements of strength of the X-ray emission, the pulse duration and the source size of the Au micro-wire backlighters. For the latter, a novel technique has been developed and successfully applied.

Short pulse, high resolution, backlighters for point projection high-energy radiography at the National Ignition Facility

DOE PAGES

Tommasini, R.; Bailey, C.; Bradley, D. K.; ...

2017-05-09

High-resolution, high-energy X-ray backlighters are very active area of research for radiography experiments at the National Ignition Facility (NIF) [Miller et al., Nucl. Fusion 44, S228 (2004)], in particular those aiming at obtaining Compton-scattering produced radiographs from the cold, dense fuel surrounding the hot spot. We report on experiments to generate and characterize point-projection-geometry backlighters using short pulses from the advanced radiographic capability (ARC) [Crane et al., J. Phys. 244, 032003 (2010); Di Nicola et al., Proc. SPIE 2015, 93450I-12], at the NIF, focused on Au micro-wires. We show the first hard X-ray radiographs, at photon energies exceeding 60 keV,more » of static objects obtained with 30 ps-long ARC laser pulses, and the measurements of strength of the X-ray emission, the pulse duration and the source size of the Au micro-wire backlighters. For the latter, a novel technique has been developed and successfully applied.« less

Thermal Spray Coatings for High-Temperature Corrosion Protection in Biomass Co-Fired Boilers

NASA Astrophysics Data System (ADS)

Oksa, M.; Metsäjoki, J.; Kärki, J.

2015-01-01

There are over 1000 biomass boilers and about 500 plants using waste as fuel in Europe, and the numbers are increasing. Many of them encounter serious problems with high-temperature corrosion due to detrimental elements such as chlorides, alkali metals, and heavy metals. By HVOF spraying, it is possible to produce very dense and well-adhered coatings, which can be applied for corrosion protection of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation for 5900 h at 550 and 750 °C. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo, and Ni-Cr-Ti. CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-Cr coating structures. Reference materials were ferritic steel T92 and nickel super alloy A263. The circulating fluidized bed boiler burnt a mixture of wood, peat and coal. The coatings showed excellent corrosion resistance at 550 °C compared to the ferritic steel. At higher temperature, NiCr sprayed with CJS had the best corrosion resistance. IN625 was consumed almost completely during the exposure at 750 °C.

Method and closing pores in a thermally sprayed doped lanthanum chromite interconnection layer

DOEpatents

Singh, Prabhakar; Ruka, Roswell J.

1995-01-01

A dense, substantially gas-tight electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an air electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO.sub.3 particles doped with an element or elements selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by thermal spraying doped LaCrO.sub.3 particles, either by plasma arc spraying or flame spraying; (C) depositing a mixture of CaO and Cr.sub.2 O.sub.3 on the surface of the thermally sprayed layer; and (D) heating the doped LaCrO.sub.3 layer coated with CaO and Cr.sub.2 O.sub.3 surface deposit at from about 1000.degree. C. to 1200.degree. C. to substantially close the pores, at least at a surface, of the thermally sprayed doped LaCrO.sub.3 layer. The result is a dense, substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the nonselected portion of the air electrode. A fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell, for example for generation of electrical power.

Method and closing pores in a thermally sprayed doped lanthanum chromite interconnection layer

DOEpatents

Singh, P.; Ruka, R.J.

1995-02-14

A dense, substantially gas-tight electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an air electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO{sub 3} particles doped with an element or elements selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by thermal spraying doped LaCrO{sub 3} particles, either by plasma arc spraying or flame spraying; (C) depositing a mixture of CaO and Cr{sub 2}O{sub 3} on the surface of the thermally sprayed layer; and (D) heating the doped LaCrO{sub 3} layer coated with CaO and Cr{sub 2}O{sub 3} surface deposit at from about 1,000 C to 1,200 C to substantially close the pores, at least at a surface, of the thermally sprayed doped LaCrO{sub 3} layer. The result is a dense, substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the nonselected portion of the air electrode. A fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell, for example for generation of electrical power. 5 figs.

Study on the Shielding Effectiveness of an Arc Thermal Metal Spraying Method against an Electromagnetic Pulse

PubMed Central

Lee, Han-Seung; Choe, Hong-Bok; Baek, In-Young

2017-01-01

An electromagnetic pulse (EMP) explodes in real-time and causes critical damage within a short period to not only electric devices, but also to national infrastructures. In terms of EMP shielding rooms, metal plate has been used due to its excellent shielding effectiveness (SE). However, it has difficulties in manufacturing, as the fabrication of welded parts of metal plates and the cost of construction are non-economical. The objective of this study is to examine the applicability of the arc thermal metal spraying (ATMS) method as a new EMP shielding method to replace metal plate. The experimental parameters, metal types (Cu, Zn-Al), and coating thickness (100–700 μm) used for the ATMS method were considered. As an experiment, a SE test against an EMP in the range of 103 to 1010 Hz was conducted. Results showed that the ATMS coating with Zn-Al had similar shielding performance in comparison with metal plate. In conclusion, the ATMS method is judged to have a high possibility of actual application as a new EMP shielding material. PMID:28976931

Study on the Shielding Effectiveness of an Arc Thermal Metal Spraying Method against an Electromagnetic Pulse.

PubMed

Lee, Han-Seung; Choe, Hong-Bok; Baek, In-Young; Singh, Jitendra Kumar; Ismail, Mohamed A

2017-10-04

An electromagnetic pulse (EMP) explodes in real-time and causes critical damage within a short period to not only electric devices, but also to national infrastructures. In terms of EMP shielding rooms, metal plate has been used due to its excellent shielding effectiveness (SE). However, it has difficulties in manufacturing, as the fabrication of welded parts of metal plates and the cost of construction are non-economical. The objective of this study is to examine the applicability of the arc thermal metal spraying (ATMS) method as a new EMP shielding method to replace metal plate. The experimental parameters, metal types (Cu, Zn-Al), and coating thickness (100-700 μm) used for the ATMS method were considered. As an experiment, a SE test against an EMP in the range of 103 to 1010 Hz was conducted. Results showed that the ATMS coating with Zn-Al had similar shielding performance in comparison with metal plate. In conclusion, the ATMS method is judged to have a high possibility of actual application as a new EMP shielding material.

Field experiment on spray drift: deposition and airborne drift during application to a winter wheat crop.

PubMed

Wolters, André; Linnemann, Volker; van de Zande, Jan C; Vereecken, Harry

2008-11-01

A field experiment was performed to evaluate various techniques for measuring spray deposition and airborne drift during spray application to a winter wheat crop. The application of a spraying agent containing the fluorescent dye Brilliant Sulfo Flavine by a conventional boom sprayer was done according to good agricultural practice. Deposition was measured by horizontal collectors in various arrangements in and outside the treated area. Airborne spray drift was measured both with a passive and an active air collecting system. Spray deposits on top of the treated canopy ranged between 68 and 71% of the applied dose and showed only small differences for various arrangements of the collectors. Furthermore, only small variations were measured within the various groups of collectors used for these arrangements. Generally, the highest spray deposition outside the treated area was measured close to the sprayed plot and was accompanied by a high variability of values, while a rapid decline of deposits was detected in more remote areas. Estimations of spray deposits with the IMAG Drift Calculator were in accordance with experimental findings only for areas located at a distance of 0.5-4.5 m from the last nozzle, while there was an overestimation of a factor of 4 at a distance of 2.0-3.0 m, thus revealing a high level of uncertainty of the estimation of deposition for short distances. Airborne spray drift measured by passive and active air collecting systems was approximately at the same level, when taking into consideration the collector efficiency of the woven nylon wire used as sampling material for the passive collecting system. The maximum value of total airborne spray drift for both spray applications (0.79% of the applied dose) was determined by the active collecting system. However, the comparatively high variability of measurements at various heights above the soil by active and passive collecting systems revealed need for further studies to elucidate the spatial pattern of airborne spray drift.

Space Shuttle Columbia Aging Wiring Failure Analysis

NASA Technical Reports Server (NTRS)

McDaniels, Steven J.

2005-01-01

A Space Shuttle Columbia main engine controller 14 AWG wire short circuited during the launch of STS-93. Post-flight examination divulged that the wire had electrically arced against the head of a nearby bolt. More extensive inspection revealed additional damage to the subject wire, and to other wires as well from the mid-body of Columbia. The shorted wire was to have been constructed from nickel-plated copper conductors surrounded by the polyimide insulation Kapton, top-coated with an aromatic polyimide resin. The wires were analyzed via scanning electron microscope (SEM), energy dispersive X-Ray spectroscopy (EDX), and electron spectroscopy for chemical analysis (ESCA); differential scanning calorimetry (DSC) and thermal gravimetric analysis (TGA) were performed on the polyimide. Exemplar testing under laboratory conditions was performed to replicate the mechanical damage characteristics evident on the failed wires. The exemplar testing included a step test, where, as the name implies, a person stepped on a simulated wire bundle that rested upon a bolt head. Likewise, a shear test that forced a bolt head and a torque tip against a wire was performed to attempt to damage the insulation and conductor. Additionally, a vibration test was performed to determine if a wire bundle would abrade when vibrated against the head of a bolt. Also, an abrasion test was undertaken to determine if the polyimide of the wire could be damaged by rubbing against convolex helical tubing. Finally, an impact test was performed to ascertain if the use of the tubing would protect the wire from the strike of a foreign object.

On the Interplay Between Adhesion Strength and Tensile Properties of Thermal Spray Coated Laminates—Part II: Low-Velocity Thermal Spray Coatings

NASA Astrophysics Data System (ADS)

Luo, Xiaotao; Smith, Gregory M.; Sampath, Sanjay

2018-02-01

In this two-part study, uniaxial tensile testing was used to evaluate coating/substrate bonding and compared with traditional ASTM C633 bond pull test results for thermal spray (TS) coated steel laminates. In Part I, the rationale, methodology, and applicability of the test to high-velocity TS coatings were demonstrated. In this Part II, the method was investigated for low-velocity TS processes (air plasma spray and arc spray) on equivalent materials. Ni and Ni-5wt.%Al coatings were deposited on steel substrates with three different roughness levels and tested using both uniaxial tensile and ASTM C633 methods. The results indicate the uniaxial tensile approach provides useful information about the nature of the coating/substrate bonding and goes beyond the traditional bond pull test in providing insightful information on the load sharing processes across the interface. Additionally, this proposed methodology alleviates some of the longstanding shortcomings and potentially reduces error associated with the traditional ASTM C633 test. The mechanisms governing the load transfer between the substrate and the coating were investigated, and the influence of Al in the coating material evaluated.

Profiling stainless steel welding processes to reduce fume emissions, hexavalent chromium emissions and operating costs in the workplace

PubMed Central

Keane, Michael; Siert, Arlen; Stone, Samuel; Chen, Bean T.

2016-01-01

Nine gas metal arc welding (GMAW) processes for stainless steel were assessed for fume generation rates, fume generation rates per g of electrode consumed, and emission rates for hexavalent chromium (Cr6+). Elemental manganese, nickel, chromium, iron emissions per unit length of weld and labor plus consumables costs were similarly measured. Flux-cored arc welding and shielded metal arc (SMAW) processes were also studied. The objective was to identify the best welding processes for reducing workplace exposures, and estimate costs for all processes. Using a conical chamber, fumes were collected, weighed, recovered and analyzed by inductively-coupled atomic emission spectroscopy for metals, and by ion chromatography for Cr6+. GMAW processes used were Surface Tension Transfer™, Regulated Metal Deposition™, Cold Metal Transfer™, short-circuit, axial spray, and pulsed spray modes. Flux-cored welding used gas shielding; SMAW used E308 rods. Costs were estimated as dollars per m length of a ¼ in (6.3 mm) thick horizontal butt weld; equipment costs were estimated as ratios of new equipment costs to a 250 ampere capacity SMAW welding machine. Results indicate a broad range of fume emission factors for the processes studied. Fume emission rates per g of electrode were lowest for GMAW processes such as pulsed-spray mode (0.2 mg/g), and highest for SMAW (8 mg fume/g electrode). Emission rates of Cr6+ ranged from 50 to 7800 μg/min, and Cr6+ generation rates per g electrode ranged from 1 to 270μg/g. Elemental Cr generation rates spanned 13 to 330μg/g. Manganese emission rates ranged from 50 to 300μg/g. Nickel emission rates ranged from 4 to140 μg/g. Labor and consumables costs ranged from $3.15 (GMAW pulsed spray) to $7.40 (SMAW) per meter of finished weld, and were measured or estimated for all 11 processes tested. Equipment costs for some processes may be as much as 5 times the cost of a typical SMAW welding machine. The results show that all of the GMAW processes in this study can substantially reduce fume, Cr6+, manganese and costs relative to SMAW, the most commonly used welding process, and several have exceptional capabilities for reducing emissions. PMID:26267301

Profiling stainless steel welding processes to reduce fume emissions, hexavalent chromium emissions and operating costs in the workplace.

PubMed

Keane, Michael; Siert, Arlen; Stone, Samuel; Chen, Bean T

2016-01-01

Nine gas metal arc welding (GMAW) processes for stainless steel were assessed for fume generation rates, fume generation rates per g of electrode consumed, and emission rates for hexavalent chromium (Cr(6+)). Elemental manganese, nickel, chromium, iron emissions per unit length of weld, and labor plus consumables costs were similarly measured. Flux-cored arc welding and shielded metal arc (SMAW) processes were also studied. The objective was to identify the best welding processes for reducing workplace exposures, and estimate costs for all processes. Using a conical chamber, fumes were collected, weighed, recovered, and analyzed by inductively coupled atomic emission spectroscopy for metals, and by ion chromatography for Cr(6+). GMAW processes used were Surface Tension Transfer, Regulated Metal Deposition, Cold Metal Transfer, short-circuit, axial spray, and pulsed spray modes. Flux-cored welding used gas shielding; SMAW used E308 rods. Costs were estimated as dollars per m length of a ¼ in (6.3 mm) thick horizontal butt weld; equipment costs were estimated as ratios of new equipment costs to a 250 ampere capacity SMAW welding machine. Results indicate a broad range of fume emission factors for the processes studied. Fume emission rates per g of electrode were lowest for GMAW processes such as pulsed-spray mode (0.2 mg/g), and highest for SMAW (8 mg fume/g electrode). Emission rates of Cr(6+) ranged from 50-7800 µg/min, and Cr(6+) generation rates per g electrode ranged from 1-270 µg/g. Elemental Cr generation rates spanned 13-330 µg/g. Manganese emission rates ranged from 50-300 µg/g. Nickel emission rates ranged from 4-140 µg/g. Labor and consumables costs ranged from $3.15 (GMAW pulsed spray) to $7.40 (SMAW) per meter of finished weld, and were measured or estimated for all 11 processes tested. Equipment costs for some processes may be as much as five times the cost of a typical SMAW welding machine. The results show that all of the GMAW processes in this study can substantially reduce fume, Cr(6+), manganese and costs relative to SMAW, the most commonly used welding process, and several have exceptional capabilities for reducing emissions.

Producing Production Level Tooling in Prototype Timing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mc Hugh, Kevin Matthew; Knirsch, J.

A new rapid solidification process machine will be able to produce eight-inch diameter by six-inch thick finished cavities at the rate of one per hour - a rate that will change the tooling industry dramatically. Global Metal Technologies, Inc. (GMTI) (Solon, OH) has signed an exclusive license with Idaho National Engineered and Environmental Laboratories (INEEL) (Idaho Falls, ID) for the development and commercialization of the rapid solidification process (RSP tooling). The first production machine is scheduled for delivery in July 2001. The RSP tooling process is a method of producing production level tooling in prototype timing. The process' inventor, Kevinmore » McHugh, describes it as a rapid solidification method, which differentiates it from the standard spray forming methods. RSP itself is relatively straightforward. Molten metal is sprayed against the ceramic pattern, replicating the pattern's contours, surface texture and details. After spraying, the molten tool steel is cooled at room temperature and separated from the pattern. The irregular periphery of the freshly sprayed insert is squared off, either by machining or, in the case of harder tool steels, by wire EDM. XX« less

Novel Approach in the Use of Plasma Spray: Preparation of Bulk Titanium for Bone Augmentations

PubMed Central

Fousova, Michaela; Vojtech, Dalibor; Jablonska, Eva; Fojt, Jaroslav; Lipov, Jan

2017-01-01

Thermal plasma spray is a common, well-established technology used in various application fields. Nevertheless, in our work, this technology was employed in a completely new way; for the preparation of bulk titanium. The aim was to produce titanium with properties similar to human bone to be used for bone augmentations. Titanium rods sprayed on a thin substrate wire exerted a porosity of about 15%, which yielded a significant decrease of Young′s modulus to the bone range and provided rugged topography for enhanced biological fixation. For the first verification of the suitability of the selected approach, tests of the mechanical properties in terms of compression, bending, and impact were carried out, the surface was characterized, and its compatibility with bone cells was studied. While preserving a high enough compressive strength of 628 MPa, the elastic modulus reached 11.6 GPa, thus preventing a stress-shielding effect, a generally known problem of implantable metals. U-2 OS and Saos-2 cells derived from bone osteosarcoma grown on the plasma-sprayed surface showed good viability. PMID:28837101

Effect of species and panel density on durability of structural flakeboard

Treesearch

M. W. Kelly; Eddie W. Price

1985-01-01

Structural flakeboard panels made with species of sweetgum, hickories, red oaks, white oaks, and southern pines, and with a 20 percent mixture of each species group, were subjected to a series of exposure conditions. One of the exposure conditions consisted of a Xenon arc lamp with an intermittent water spray from conventional weatherometer test equipment. Other...

Planar controlled zone microwave plasma system

DOEpatents

Ripley, Edward B [Knoxville, TN; Seals, Roland D [Oak Ridge, TN; Morrell, Jonathan S [Knoxvlle, TN

2011-10-04

An apparatus and method for initiating a process gas plasma. A conductive plate having a plurality of conductive fingers is positioned in a microwave applicator. An arc forms between the conductive fingers to initiate the formation of a plasma. A transport mechanism may convey process materials through the plasma. A spray port may be provided to expel processed materials.

Controlled zone microwave plasma system

DOEpatents

Ripley, Edward B [Knoxville, TN; Seals, Roland D [Oak Ridge, TN; Morrell, Jonathan S [Knoxville, TN

2009-10-20

An apparatus and method for initiating a process gas plasma. A conductive plate having a plurality of conductive fingers is positioned in a microwave applicator. An arc forms between the conductive fingers to initiate the formation of a plasma. A transport mechanism may convey process materials through the plasma. A spray port may be provided to expel processed materials.

Program Supports Scientific Visualization

NASA Technical Reports Server (NTRS)

Keith, Stephan

1994-01-01

Primary purpose of General Visualization System (GVS) computer program is to support scientific visualization of data generated by panel-method computer program PMARC_12 (inventory number ARC-13362) on Silicon Graphics Iris workstation. Enables user to view PMARC geometries and wakes as wire frames or as light shaded objects. GVS is written in C language.

Wiring up pre-characterized single-photon emitters by laser lithography

NASA Astrophysics Data System (ADS)

Shi, Q.; Sontheimer, B.; Nikolay, N.; Schell, A. W.; Fischer, J.; Naber, A.; Benson, O.; Wegener, M.

2016-08-01

Future quantum optical chips will likely be hybrid in nature and include many single-photon emitters, waveguides, filters, as well as single-photon detectors. Here, we introduce a scalable optical localization-selection-lithography procedure for wiring up a large number of single-photon emitters via polymeric photonic wire bonds in three dimensions. First, we localize and characterize nitrogen vacancies in nanodiamonds inside a solid photoresist exhibiting low background fluorescence. Next, without intermediate steps and using the same optical instrument, we perform aligned three-dimensional laser lithography. As a proof of concept, we design, fabricate, and characterize three-dimensional functional waveguide elements on an optical chip. Each element consists of one single-photon emitter centered in a crossed-arc waveguide configuration, allowing for integrated optical excitation and efficient background suppression at the same time.

Reliability analysis of forty-five strain-gage systems mounted on the first fan stage of a YF-100 engine

NASA Technical Reports Server (NTRS)

Holanda, R.; Frause, L. M.

1977-01-01

The reliability of 45 state-of-the-art strain gage systems under full scale engine testing was investigated. The flame spray process was used to install 23 systems on the first fan rotor of a YF-100 engine; the others were epoxy cemented. A total of 56 percent of the systems failed in 11 hours of engine operation. Flame spray system failures were primarily due to high gage resistance, probably caused by high stress levels. Epoxy system failures were principally erosion failures, but only on the concave side of the blade. Lead-wire failures between the blade-to-disk jump and the control room could not be analyzed.

Sensing of metal-transfer mode for process control of GMAW (gas metal arc welding)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Carlson, N.M.; Johnson, J.A.; Smartt, H.B.

1989-01-01

One of the requirements of a sensing system for feedback control of gas metal arc welding (GMAW) is the capability to determine the metal-transfer mode. Because the operating boundary for the desired transfer mode, expressed as a function of mass input and heat input, may vary due to conditions beyond the control of the system, a means of detecting the transfer mode during welding is necessary. A series of sensing experiments was performed during which the ultrasonic emissions, audio emissions, welding current fluctuations and welding voltage fluctuations were recorded as a function of the transfer mode. In addition, high speedmore » movies (5000 frames/s) of the droplet formation and detachment were taken synchronously with the sensing data. An LED mounted in the camera was used to mark the film at the beginning and end of the data acquisition period. A second LED was pulsed at a 1 kHz rate and the pulses recorded on film and with the sensor data. Thus events recorded on the film can be correlated with the sensor data. Data acquired during globular transfer, spray transfer, and stiff spray or streaming transfer were observed to correlate with droplet detachment and arc shorting. The audio, current, and voltage data can be used to discriminate among these different transfer modes. However, the current and voltage data are also dependent on the characteristic of the welding power supply. 5 refs., 3 figs., 1 tab.« less

Effects of alloying element on weld characterization of laser-arc hybrid welding of pure copper

NASA Astrophysics Data System (ADS)

Hao, Kangda; Gong, Mengcheng; Xie, Yong; Gao, Ming; Zeng, Xiaoyan

2018-06-01

Effects of alloying elements of Si and Sn on weld characterizations of laser-arc hybrid welded pure copper (Cu) with thickness of 2 mm was studied in detail by using different wires. The weld microstructure was analyzed, and the mechanical properties (micro-hardness and tensile property), conductivity and corrosion resistance were tested. The results showed that the alloying elements benefit the growth of column grains within weld fusion zone (FZ), increase the ultimate tensile strength (UTS) of the FZ and weld corrosion resistance, and decrease weld conductivity. The mechanisms were discussed according to the results.

The Effect of Filler Wire and Flux Compositions on the Microstructure and Properties of Microalloyed Steel Weld Metal.

DTIC Science & Technology

1984-08-01

obtained from subsize (5.0 x 10.0 x 55.0 mm) Charpy V-Notch specimens, subsize (7.6 x 7.6 x 55.0 mm)-Izod specimens, and subsize (5.0 x 9.5 x 101.6 mm...47 15. Schematic of a submerged arc weld showing the dimensions and orientation of subsize Charpy V-Notch specimens... Subsize (5.0 x 10.0 x 55.0 mm) Charpy impact values P of two submerged arc welds performed on quenched and tempered C-Mn-Mo-Nb plate as a function of

Investigation on microstructure and mechanical properties on pulsed current gas tungsten arc welded super alloy 617

NASA Astrophysics Data System (ADS)

Mageshkumar, K.; Kuppan, P.; Arivazhagan, N.

2017-11-01

The present research work investigates the metallurgical and mechanical properties of weld joint fabricated by alloy 617 by pulsed current gas tungsten arc welding (PCGTAW) technique. Welding was done by ERNiCrCoMo-1 filler wire. Optical and Scanning Electron Microscope (SEM) revealed the fine equiaxed dendritic in the fusion zone. Electron Dispersive Spectroscopy (EDS) demonstrates the presence of Mo-rich secondary phases in the grain boundary regions. Tensile test shows improved mechanical properties compared to the continuous current mode. Bend test didn’t indicate the presence of defects in the weldments.

Size-separated particle fractions of stainless steel welding fume particles - A multi-analytical characterization focusing on surface oxide speciation and release of hexavalent chromium.

PubMed

Mei, N; Belleville, L; Cha, Y; Olofsson, U; Odnevall Wallinder, I; Persson, K-A; Hedberg, Y S

2018-01-15

Welding fume of stainless steels is potentially health hazardous. The aim of this study was to investigate the manganese (Mn) and chromium (Cr) speciation of welding fume particles and their extent of metal release relevant for an inhalation scenario, as a function of particle size, welding method (manual metal arc welding, metal arc welding using an active shielding gas), different electrodes (solid wires and flux-cored wires) and shielding gases, and base alloy (austenitic AISI 304L and duplex stainless steel LDX2101). Metal release investigations were performed in phosphate buffered saline (PBS), pH 7.3, 37°, 24h. The particles were characterized by means of microscopic, spectroscopic, and electroanalytical methods. Cr was predominantly released from particles of the welding fume when exposed in PBS [3-96% of the total amount of Cr, of which up to 70% as Cr(VI)], followed by Mn, nickel, and iron. Duplex stainless steel welded with a flux-cored wire generated a welding fume that released most Cr(VI). Nano-sized particles released a significantly higher amount of nickel compared with micron-sized particle fractions. The welding fume did not contain any solitary known chromate compounds, but multi-elemental highly oxidized oxide(s) (iron, Cr, and Mn, possibly bismuth and silicon). Copyright © 2017 The Authors. Published by Elsevier B.V. All rights reserved.

Microstructure and Mechanical Properties of Plasma Arc Brazed AISI 304L Stainless Steel and Galvanized Steel Plates

NASA Astrophysics Data System (ADS)

Jin, Yajuan; Li, Ruifeng; Yu, Zhishui; Wang, Yu

2016-04-01

Plasma arc brazing is used to join the AISI 304L stainless steel and galvanized steel plate butt joints with the CuSi3Mn1 filler wire. The effect of parameters on weld surface appearance, interfacial microstructure, and composition distribution in the joint was studied. The microhardness and mechanical tests were conducted to determine the mechanical properties of the welded specimens. The results indicated that good appearance, bead shape, and sufficient metallurgical bonding could be obtained when the brazing process was performed with a wire feeding speed of 0.8 m/min, plasma gas flow rate of 3.0 l/min, welding current of 100 A, and welding speed of 27 cm/min. During plasma arc brazing process, the top corner of the stainless steel and galvanized steel plate were heated and melted, and the melted quantity of stainless steel was much more than that of the galvanized steel due to the thermal conductivity coefficient difference between the dissimilar materials. The microhardness test results shows that the microhardness value gradually increased from the side of the galvanized steel to the stainless steel in the joint, and it is good for improving the mechanical properties of joint. The tensile strength was a little higher than that of the brazing filler, and the fracture position of weld joint was at the base metal of galvanized steel plate.

High pressure neon arc lamp

DOEpatents

Sze, Robert C.; Bigio, Irving J.

2003-07-15

A high pressure neon arc lamp and method of using the same for photodynamic therapies is provided. The high pressure neon arc lamp includes a housing that encloses a quantity of neon gas pressurized to about 500 Torr to about 22,000 Torr. At each end of the housing the lamp is connected by electrodes and wires to a pulse generator. The pulse generator generates an initial pulse voltage to breakdown the impedance of the neon gas. Then the pulse generator delivers a current through the neon gas to create an electrical arc that emits light having wavelengths from about 620 nanometers to about 645 nanometers. A method for activating a photosensitizer is provided. Initially, a photosensitizer is administered to a patient and allowed time to be absorbed into target cells. Then the high pressure neon arc lamp is used to illuminate the target cells with red light having wavelengths from about 620 nanometers to about 645 nanometers. The red light activates the photosensitizers to start a chain reaction that may involve oxygen free radicals to destroy the target cells. In this manner, a high pressure neon arc lamp that is inexpensive and efficiently generates red light useful in photodynamic therapy is provided.

Spatial structure of the arc in a pulsed GMAW process

NASA Astrophysics Data System (ADS)

Kozakov, R.; Gött, G.; Schöpp, H.; Uhrlandt, D.; Schnick, M.; Häßler, M.; Füssel, U.; Rose, S.

2013-06-01

A pulsed gas metal arc welding (GMAW) process of steel under argon shielding gas in the globular mode is investigated by measurements and simulation. The analysis is focussed on the spatial structure of the arc during the current pulse. Therefore, the radial profiles of the temperature, the metal vapour species and the electric conductivity are determined at different heights above the workpiece by optical emission spectroscopy (OES). It is shown that under the presence of metal vapour the temperature minimum occurs at the centre of the arc. This minimum is preserved at different axial positions up to 1 mm above the workpiece. In addition, estimations of the electric field in the arc from the measurements are given. All these results are compared with magneto-hydrodynamic simulations which include the evaporation of the wire material and the change of the plasma properties due to the metal vapour admixture in particular. The experimental method and the simulation model are validated by means of the satisfactory correspondence between the results. Possible reasons for the remaining deviations and improvements of the methods which should be aspired are discussed.

Design, construction, and characterization of a novel robotic welding fume generator and inhalation exposure system for laboratory animals.

PubMed

Antonini, James M; Afshari, Aliakbar A; Stone, Sam; Chen, Bean; Schwegler-Berry, Diane; Fletcher, W Gary; Goldsmith, W Travis; Vandestouwe, Kurt H; McKinney, Walter; Castranova, Vincent; Frazer, David G

2006-04-01

Respiratory effects observed in welders have included lung function changes, metal fume fever, bronchitis, and a possible increase in the incidence of lung cancer. Many questions remain unanswered regarding the causality and possible underlying mechanisms associated with the potential toxic effects of welding fume inhalation. The objective of the present study was to construct a completely automated, computer-controlled welding fume generation and inhalation exposure system to simulate real workplace exposures. The system comprised a programmable six-axis robotic welding arm, a water-cooled arc welding torch, and a wire feeder that supplied the wire to the torch at a programmed rate. For the initial studies, gas metal arc welding was performed using a stainless steel electrode. A flexible trunk was attached to the robotic arm of the welder and was used to collect and transport fume from the vicinity of the arc to the animal exposure chamber. Undiluted fume concentrations consistently ranged from 90-150 mg/m(3) in the animal chamber during welding. Temperature and humidity remained constant in the chamber during the welding operation. The welding particles were composed of (from highest to lowest concentration) iron, chromium, manganese, and nickel as measured by inductively coupled plasma atomic emission spectroscopy. Size distribution analysis indicated the mass median aerodynamic diameter of the generated particles to be approximately 0.24 microm with a geometric standard deviation (sigma(g)) of 1.39. As determined by transmission and scanning electron microscopy, the generated aerosols were mostly arranged as chain-like agglomerates of primary particles. Characterization of the laboratory-generated welding aerosol has indicated that particle morphology, size, and chemical composition are comparable to stainless steel welding fume generated in other studies. With the development of this novel system, it will be possible to establish an animal model using controlled welding exposures from automated gas metal arc and flux-cored arc welding processes to investigate how welding fumes affect health.

The mechanical stability of polyimide films at high pH

NASA Technical Reports Server (NTRS)

Croall, Catharine I.; St.clair, Terry L.

1990-01-01

Polyimide insulated electrical wire has been widely used in the aerospace industry in commercial, military, and to a lesser degree, general aviation aircraft since the early 1970s. Wiring failures linked to insulation damage have drawn much attention in the media and concerns have developed regarding the long term stability and safety of polyimide insulated electrical wire. The mechanical durability and chemical stability of polyimide insulated wire are affected by hydrolysis, notch propagation, wet and dry arc tracking, topcoat flaking, and degradation due to high pH fluids. Several polyimides were selected for evaluation for resistance to degradation by various aqueous alkaline solutions. The polyimides under evaluation include commercially available films such as KAPTON (tradename), APICAL (tradename), LARC-TPI, and UPILEX (tradename) R and S, as well as a number of experimental films prepared at NASA-Langley. Material properties investigated include viscosity, solubility, moisture absorption, glass transition temperature, dielectric constant, and mechanical properties before and after exposure to various conditions.

Wire Arc Additive Manufacturing of AZ31 Magnesium Alloy: Grain Refinement by Adjusting Pulse Frequency.

PubMed

Guo, Jing; Zhou, Yong; Liu, Changmeng; Wu, Qianru; Chen, Xianping; Lu, Jiping

2016-10-09

Wire arc additive manufacturing (WAAM) offers a potential approach to fabricate large-scale magnesium alloy components with low cost and high efficiency, although this topic is yet to be reported in literature. In this study, WAAM is preliminarily applied to fabricate AZ31 magnesium. Fully dense AZ31 magnesium alloy components are successfully obtained. Meanwhile, to refine grains and obtain good mechanical properties, the effects of pulse frequency (1, 2, 5, 10, 100, and 500 Hz) on the macrostructure, microstructure and tensile properties are investigated. The results indicate that pulse frequency can result in the change of weld pool oscillations and cooling rate. This further leads to the change of the grain size, grain shape, as well as the tensile properties. Meanwhile, due to the resonance of the weld pool at 5 Hz and 10 Hz, the samples have poor geometry accuracy but contain finer equiaxed grains (21 μm) and exhibit higher ultimate tensile strength (260 MPa) and yield strength (102 MPa), which are similar to those of the forged AZ31 alloy. Moreover, the elongation of all samples is above 23%.

Fume generation rates for stainless steel, nickel and aluminum alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Castner, H.R.

1996-12-01

This paper describes a study of the effects of pulsed welding current on fume produced during gas metal arc welding (GMAW) of stainless steel, nickel, and aluminum alloys. This is an extension of earlier studies of mild steel electrode wire. Reduction of welding fume is important because steady current GMAW of stainless steels and nickel alloys may produce fume that exceeds recommended worker exposure limits for some of the fume constituents. Fume generation from aluminum alloy ER5356 was studied because steady current welding with this alloy produces much higher fume generation rates than ER4043 alloy electrode wire. This work showsmore » that pulsed current can reduce GMAW fume generation rates for Er308L, ER310, and ER312 stainless steel, ERNiCr-3 nickel alloy, and ER5356 aluminum-magnesium alloy electrode wires.« less

Detecting fiducials affected by trombone delay in ARC and the main laser alignment at the National Ignition Facility

NASA Astrophysics Data System (ADS)

Awwal, Abdul A. S.; Bliss, Erlan S.; Miller Kamm, Victoria; Leach, Richard R.; Roberts, Randy; Rushford, Michael C.; Lowe-Webb, Roger; Wilhelmsen, Karl

2015-09-01

Four of the 192 beams of the National Ignition Facility (NIF) are currently being diverted into the Advanced Radiographic Capability (ARC) system to generate a sequence of short (1-50 picoseconds) 1053 nm laser pulses. When focused onto high Z wires in vacuum, these pulses create high energy x-ray pulses capable of penetrating the dense, imploding fusion fuel plasma during ignition scale experiments. The transmitted x-rays imaged with x-ray diagnostics can create movie radiographs that are expected to provide unprecedented insight into the implosion dynamics. The resulting images will serve as a diagnostic for tuning the experimental parameters towards successful fusion reactions. Beam delays introduced into the ARC pulses via independent, free-space optical trombones create the desired x-ray image sequence, or movie. However, these beam delays cause optical distortion of various alignment fiducials viewed by alignment sensors in the NIF and ARC beamlines. This work describes how the position of circular alignment fiducials is estimated in the presence of distortion.

Metal Big Area Additive Manufacturing: Process Modeling and Validation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Simunovic, Srdjan; Nycz, Andrzej; Noakes, Mark W

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology for printing large-scale 3D objects. mBAAM is based on the gas metal arc welding process and uses a continuous feed of welding wire to manufacture an object. An electric arc forms between the wire and the substrate, which melts the wire and deposits a bead of molten metal along the predetermined path. In general, the welding process parameters and local conditions determine the shape of the deposited bead. The sequence of the bead deposition and the corresponding thermal history of the manufactured object determine the long rangemore » effects, such as thermal-induced distortions and residual stresses. Therefore, the resulting performance or final properties of the manufactured object are dependent on its geometry and the deposition path, in addition to depending on the basic welding process parameters. Physical testing is critical for gaining the necessary knowledge for quality prints, but traversing the process parameter space in order to develop an optimized build strategy for each new design is impractical by pure experimental means. Computational modeling and optimization may accelerate development of a build process strategy and saves time and resources. Because computational modeling provides these opportunities, we have developed a physics-based Finite Element Method (FEM) simulation framework and numerical models to support the mBAAM process s development and design. In this paper, we performed a sequentially coupled heat transfer and stress analysis for predicting the final deformation of a small rectangular structure printed using the mild steel welding wire. Using the new simulation technologies, material was progressively added into the FEM simulation as the arc weld traversed the build path. In the sequentially coupled heat transfer and stress analysis, the heat transfer was performed to calculate the temperature evolution, which was used in a stress analysis to evaluate the residual stresses and distortions. In this formulation, we assume that physics is directionally coupled, i.e. the effect of stress of the component on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.« less

Problems with aging wiring in Naval aircraft

NASA Technical Reports Server (NTRS)

Campbell, Frank J.

1994-01-01

The Navy is experiencing a severe aircraft electrical wiring maintenance problem as a result of the extensive use of an aromatic polyimide insulation that is deteriorating at a rate that was unexpected when this wire was initially selected. This problem has significantly affected readiness, reliability, and safety and has greatly increased the cost of ownership of Naval aircraft. Failures in wire harnesses have exhibited arcing and burning that will propagate drastically, to the interruption of many electrical circuits from a fault initiated by the failure of deteriorating wires. There is an urgent need for a capability to schedule aircraft rewiring in an orderly manner with a logically derived determination of which aircraft have aged to the point of absolute necessity. Excessive maintenance was demonstrated to result from the accelerated aging due to the parameters of moisture, temperature, and strain that exist in the Naval Aircraft environment. Laboratory studies have demonstrated that MIL-W-81381 wire insulation when aged at high humidities followed the classical Arrhenius thermal aging relationship. In an extension of the project a multifactor formula was developed that is now capable of predicting life under varying conditions of these service parameters. An automated test system has also been developed to analyze the degree of deterioration that has occurred in wires taken from an aircraft in order to obtain an assessment of remaining life. Since it is both physically and financially impossible to replace the wiring in all the Navy's aircraft at once, this system will permit expedient scheduling so that those aircraft that are most probable to have wiring failure problems can be overhauled first.

Influence of photostabilizers on wood flour-HDPE composites exposed to xenon-arc radiation with and without water spray

Treesearch

Nicole M. Stark; Laurent M. Matuana

2006-01-01

The weathering of wood-plastic composites changes their appearance and/or mechanical properties. These changes can be slowed through the addition of ultraviolet absorbers and pigments. The first phase of this study examined the effect of incorporating different concentrations of an ultraviolet absorber and/or pigment into wood-flour-filled high-density polyethylene (WF...

Development of a fluid model for DC arc plasma torches and its integration with downstream models of atmospheric plasma spray particle plumes

NASA Astrophysics Data System (ADS)

Cannamela, Michael J., III

The plasma spray process uses plasma flames to melt micron sized particles of e.g. ceramic and propel the droplets to impinge upon and freeze to the target workpiece, forming a functional coating. Variations in the process arise from many sources, and because sensing of the process is imperfect one is motivated to pursue a modeling approach. This dissertation models the major elements of the process; the torch that produces the plasma flame, the jet of hot plasma issuing from the torch, and the plume of particles conveyed and heated by the jet. The plasma in the torch is modeled by a one-fluid magnetohydrodynamic (MHD) approach and it is found that the MHD equations can accurately predict the power dissipated in the bulk of the plasma, while special treatment is required in regions near the electrodes. Treatment of the cathode region is eased since it can be de-coupled from the bulk flow. Treatment of the anode region aims to extract the correct amount of power from the plasma. With MHD in the bulk and these special conditions at the electrode boundaries, the net power into the plasma can be matched with experiment. For one simulation of an SG-100 torch operating at 500A, the measured net power was 7.0kW while the computed net power was 7.1kW. Using outlet information from the torch, the impact of plasma arc oscillations on the free jet and on the in-flight particle states is predicted. The model of the plasma jet is validated against the existing LAVA code, and is able to predict the fraction of entrained air in the jet to within 20% of the experimental value. The variations in particle states due to the arc fluctuations are found to be similar in size to variations due to changes in particle injection velocity, and so cannot be neglected when considering particle state distributions. The end result of this work is to make available a complete chain of models for the plasma spray process, from torch input conditions to in-flight particle state.

Numerical simulation of metallic wire arc additive manufacturing (WAAM)

NASA Astrophysics Data System (ADS)

Graf, M.; Pradjadhiana, K. P.; Hälsig, A.; Manurung, Y. H. P.; Awiszus, B.

2018-05-01

Additive-manufacturing technologies have been gaining tremendously in popularity for some years in the production of single-part series with complex, close-to-final-contour geometries and the processing of special or hybrid materials. In principle, the processes can be subdivided into wire-based and powder-based processes in accordance with the Association of German Engineers (VDI) Guideline 3405. A further subdivision is made with respect to the smelting technology. In all of the processes, the base material is applied in layers at the points where it is needed in accordance with the final contour. The process that was investigated was wire-based, multi-pass welding by means of gas-metal arc welding. This was accomplished in the present study by determining the material parameters (thermo-mechanical and thermo-physical characteristics) of the welding filler G3Si1 (material number: 1.5125) that were necessary for the numerical simulation and implementing them in a commercial FE program (MSC Marc Mentat). The focus of this paper was on simulation and validation with respect to geometry and microstructural development in the welding passes. The resulting minimal deviation between reality and simulation was a result of the measurement inertia of the thermocouples. In general, however, the FE model can be used to make a very good predetermination of the cooling behaviour, which affects the microstructural development and thus the mechanical properties of the joining zone, as well as the geometric design of the component (distortion, etc.).

Deep Charging Evaluation of Satellite Power and Communication System Components

NASA Technical Reports Server (NTRS)

Schneider, T. A.; Vaughn, J. A.; Chu, B.; Wong, F.; Gardiner, G.; Wright, K. H.; Phillips, B.

2016-01-01

Deep charging, in contrast to surface charging, focuses on electron penetration deep into insulating materials applied over conductors. A classic example of this scenario is an insulated wire. Deep charging can pose a threat to material integrity, and to sensitive electronics, when it gives rise to an electrostatic discharge or arc. With the advent of Electric Orbit Raising, which requires spiraling through Earth's radiation belts, satellites are subjected to high energy electron environments which they normally would not encounter. Beyond Earth orbit, missions to Jupiter and Saturn face deep charging concerns due to the high energy radiation environments. While predictions can be made about charging in insulating materials, it is difficult to extend those predictions to complicated geometries, such as the case of an insulating coating around a small wire, or a non-uniform silicone grouting on a bus bar. Therefore, to conclusively determine the susceptibility of a system to arcs from deep charging, experimental investigations must be carried out. This paper will describe the evaluation carried out by NASA's Marshall Space Flight Center on subscale flight-like samples developed by Space Systems/Loral, LLC. Specifically, deep charging evaluations of solar array wire coupons, a photovoltaic cell coupon, and a coaxial microwave transmission cable, will be discussed. The results of each evaluation will be benchmarked against control sample tests, as well as typical power system levels, to show no significant deep charging threat existed for this set of samples under the conditions tested.

Deposition stress effects on thermal barrier coating burner rig life

NASA Technical Reports Server (NTRS)

Watson, J. W.; Levine, S. R.

1984-01-01

A study of the effect of plasma spray processing parameters on the life of a two layer thermal barrier coating was conducted. The ceramic layer was plasma sprayed at plasma arc currents of 900 and 600 amps onto uncooled tubes, cooled tubes, and solid bars of Waspalloy in a lathe with 1 or 8 passes of the plasma gun. These processing changes affected the residual stress state of the coating. When the specimens were tested in a Mach 0.3 cyclic burner rig at 1130 deg C, a wide range of coating lives resulted. Processing factors which reduced the residual stress state in the coating, such as reduced plasma temperature and increased heat dissipation, significantly increased coating life.

Deposition stress effects on the life of thermal barrier coatings on burner rigs

NASA Technical Reports Server (NTRS)

Watson, J. W.; Levine, S. R.

1984-01-01

A study of the effect of plasma spray processing parameters on the life of a two layer thermal barrier coating was conducted. The ceramic layer was plasma sprayed at plasma arc currents of 900 and 600 amps onto uncooled tubes, cooled tubes, and solid bars of Waspalloy in a lathe with 1 or 8 passes of the plasma gun. These processing changes affected the residual stress state of the coating. When the specimens were tested in a Mach 0.3 cyclic burner rig at 1130 deg C, a wide range of coating lives resulted. Processing factors which reduced the residual stress state in the coating, such as reduced plasma temperature and increased heat dissipation, significantly increased coating life.

Method of forming a plasma sprayed interconnection layer on an electrode of an electrochemical cell

DOEpatents

Spengler, Charles J.; Folser, George R.; Vora, Shailesh D.; Kuo, Lewis; Richards, Von L.

1995-01-01

A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO.sub.3 particles doped with an element selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by plasma spraying doped LaCrO.sub.3 powder, preferably compensated with chromium as Cr.sub.2 O.sub.3 and/or dopant element, preferably by plasma arc spraying; and, (C) heating the doped and compensated LaCrO.sub.3 layer to about 1100.degree. C. to 1300.degree. C. to provide a dense, substantially gas-tight, substantially hydration-free, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the unselected portion of the air electrode, and a fuel electrode can be applied to the solid electrolyte, to provide an electrochemical cell.

Method of forming a plasma sprayed interconnection layer on an electrode of an electrochemical cell

DOEpatents

Spengler, C.J.; Folser, G.R.; Vora, S.D.; Kuo, L.; Richards, V.L.

1995-06-20

A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an air electrode structure of an electrochemical cell by (A) providing an electrode surface; (B) forming on a selected portion of the electrode surface, a layer of doped LaCrO{sub 3} particles doped with an element selected from Ca, Sr, Ba, Mg, Co, Ni, Al and mixtures thereof by plasma spraying doped LaCrO{sub 3} powder, preferably compensated with chromium as Cr{sub 2}O{sub 3} and/or dopant element, preferably by plasma arc spraying; and, (C) heating the doped and compensated LaCrO{sub 3} layer to about 1100 C to 1300 C to provide a dense, substantially gas-tight, substantially hydration-free, electrically conductive interconnection material bonded to the electrode surface. A solid electrolyte layer can be applied to the unselected portion of the air electrode, and a fuel electrode can be applied to the solid electrolyte, to provide an electrochemical cell. 6 figs.

Scientific, technological, and economic aspects of rapid tooling by electric arc spray forming

NASA Astrophysics Data System (ADS)

Grant, P. S.; Duncan, S. R.; Roche, A.; Johnson, C. F.

2006-12-01

For the last seven years, Oxford University and Ford Motor Company personnel have been researching jointly the development of the large-scale spray forming of steel tooling capable for use in mass production, particularly for the pressing of sheet metal in automotive applications. These investigations have involved: the comprehensive microstructure and property studies, modeling of shape evolution and heat flow, realtime feedback control of tool temperature to eliminate tool distortion, high-speed imaging and particle image velocimetry of droplet deposition on three-dimensional (3D) shapes, testing of full-scale tools for different applications in the production environment, and detailed studies of the cost and time savings realized for different tooling applications. This paper provides an overview of the scientific and technical progress to date, presents the latest results, and describes the current state-of-the-art. Many of the insights described have relevance and applicability across the family of thermal spray processes and applications.

Calculation of a vacuum system of the installation for cleaning the surface of metal rolling by a cathode spot of a vacuum arc

NASA Astrophysics Data System (ADS)

Kuznetsov, V. G.; Kurbanov, T. A.; Kostrin, D. K.

2017-07-01

In this work are presented the installations for cleaning the surface of rolled products (wire and ribbon) from scale and technological lubricant with gateway systems of open type. The calculation of gateway devices and the optimal selection of pumping systems are shown.

[Determination of fumes and their elements from flux cored arc welding].

PubMed

Matczak, Wanda; Przybylska-Stanisławska, Magdalena

2004-01-01

The aim of this work was to assay the concentration levels and composition of welding fumes, released during flux cored arc welding, to assess exposure of welders. Concentrations and welding fume components, such as iron, manganese, chromium (including the soluble and chromium VI), nickel, copper, calcium, aluminium, barium, and fluorides (including hydrogen fluoride) were determined in the air of six industrial plants (shipyards, mechanical engineering plants and a power station) at the breathing zones of the welders who used 10 types of wires during flux cored arc welding. The following determination methods were used: gravimetry (fumes), AAS (metals), and spectrophotometry (chromium VI, fluorides--including hydrogen fluoride). The results made it possible to determine the relationship between concentrations of welding fume and its elements, and to assess worker's exposure. Time weighted average concentrations of the welding fumes and its elements at the worker's breathing zone were: mg/m3: dust 0.2-24.3; Fe 0.2-6.7; Mn 0.01-1.8; Cr 0.004-0.5 (mainly Cr III); Ca 0.004-2.5; Ni < or = 0.004; Cu < 0.002-0.05; Al < 0.14-0.4; Ba < 0.14; F- 0.07-0.43. The welders using some types of flux cored welding wires worked in conditions harmful to their health owing to the considerably exceeded TLV value for fume and MAC values for manganese, and occasional slightly excessive MAC values for calcium and iron.

Performance Analysis and Modeling of Thermally Sprayed Resistive Heaters

NASA Astrophysics Data System (ADS)

Lamarre, Jean-Michel; Marcoux, Pierre; Perrault, Michel; Abbott, Richard C.; Legoux, Jean-Gabriel

2013-08-01

Many processes and systems require hot surfaces. These are usually heated using electrical elements located in their vicinity. However, this solution is subject to intrinsic limitations associated with heating element geometry and physical location. Thermally spraying electrical elements directly on surfaces can overcome these limitations by tailoring the geometry of the heating element to the application. Moreover, the element heat transfer is maximized by minimizing the distance between the heater and the surface to be heated. This article is aimed at modeling and characterizing resistive heaters sprayed on metallic substrates. Heaters were fabricated by using a plasma-sprayed alumina dielectric insulator and a wire flame-sprayed iron-based alloy resistive element. Samples were energized and kept at a constant temperature of 425 °C for up to 4 months. SEM cross-sectional observations revealed the formation of cracks at very specific locations in the alumina layer after thermal use. Finite-element modeling shows that these cracks originate from high local thermal stresses and can be predicted according to the considered geometry. The simulation model was refined using experimental parameters obtained by several techniques such as emissivity and time-dependent temperature profile (infra-red camera), resistivity (four-probe technique), thermal diffusivity (laser flash method), and mechanical properties (micro and nanoindentation). The influence of the alumina thickness and the substrate material on crack formation was evaluated.

Theoretical model and experimental investigation of current density boundary condition for welding arc study

NASA Astrophysics Data System (ADS)

Boutaghane, A.; Bouhadef, K.; Valensi, F.; Pellerin, S.; Benkedda, Y.

2011-04-01

This paper presents results of theoretical and experimental investigation of the welding arc in Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW) processes. A theoretical model consisting in simultaneous resolution of the set of conservation equations for mass, momentum, energy and current, Ohm's law and Maxwell equation is used to predict temperatures and current density distribution in argon welding arcs. A current density profile had to be assumed over the surface of the cathode as a boundary condition in order to make the theoretical calculations possible. In stationary GTAW process, this assumption leads to fair agreement with experimental results reported in literature with maximum arc temperatures of ~21 000 K. In contrast to the GTAW process, in GMAW process, the electrode is consumable and non-thermionic, and a realistic boundary condition of the current density is lacking. For establishing this crucial boundary condition which is the current density in the anode melting electrode, an original method is setup to enable the current density to be determined experimentally. High-speed camera (3000 images/s) is used to get geometrical dimensions of the welding wire used as anode. The total area of the melting anode covered by the arc plasma being determined, the current density at the anode surface can be calculated. For a 330 A arc, the current density at the melting anode surface is found to be of 5 × 107 A m-2 for a 1.2 mm diameter welding electrode.

Measurement of the densities of Cu and Ag vapours in a low-voltage switch using the hook method

NASA Astrophysics Data System (ADS)

Lins, Günter

2012-05-01

In a research model of a low-voltage circuit breaker with fixed contacts and windows for optical access, arcs powered by either a high-current transformer or a capacitor bank were initiated by the explosion of tungsten wires. Air at atmospheric pressure was the switching medium. The number densities of neutral silver and copper vapours from contacts and arc runners were measured simultaneously by the hook method using a Mach-Zehnder interferometer combined with a 1 m spectrograph and a gated intensified CCD camera. When an arc current was flowing, a substantial fraction of the metal vapour was ionized, and thus not amenable to a density measurement with the technique chosen. To nevertheless obtain approximate density values, the arc current was forced to zero within 8 to 10 µs at a preset time and measurements were carried out 100 µs after extinction of the arc. At that time the metal vapour was expected to have recombined to a large extent but not yet diffused to the walls in significant amounts. Depending on the current amplitude reached within the arc duration the arc remained anchored to the silver contacts or commutated to the copper arc runners. At a maximum current amplitude of 650 A Ag vapour densities of the order of 1022 m-3 were observed near the anode outweighing the Cu vapour density by a factor of 20. When at 1600 A the arc commutated to the arc runners a Cu vapour density of 8 × 1021 m-3 was reached while the Ag density remained limited to 2 × 1021 m-3.

A New Type of Self-lubricated Thermal Spray Coatings: Liquid Lubricants Embedded in a Metal Matrix

NASA Astrophysics Data System (ADS)

Espallargas, N.; Armada, S.

2015-01-01

Oils and greases are commonly used for lubricating, rotating and sliding systems such as bearings, gears, connectors, etc. The maintenance of such lubricated systems in some applications where access is difficult (e.g., offshore wind farms and subsea equipment) increases the operational costs. In some cases, it can be thought that the use of solid lubricants (MoS2, PTFE, graphite, etc.) embedded in coatings could be a solution for such applications; however, the mechanical and dynamic conditions of most of the systems are not appropriate for solid lubricants. Despite this, solid lubricants such as PTFE and MoS2 have been largely employed in different industries, especially in those applications where liquid lubricants cannot be used and when the dynamic conditions allow for it. Self-lubricated coatings have been a major topic of interest in thermal spray in the last decades. Although the use of liquid lubricants is desirable whenever it is possible, limited research has been addressed toward the development of self-lubricated coatings containing liquid lubricants. One of the main reasons for this is due to the complexity of embedding liquid lubricant reservoirs inside the coating matrix. In the present work, a new type of liquid-solid self-lubricated coatings is presented, being the matrix a metal alloy. Three thermal spray techniques used were as follows: arc-spray, plasma spray, and HVOAF. The metal matrices were two stainless steel types and liquid lubricant-filled capsules with different liquid contents were used. No degradation of the capsules during spraying was observed and the coatings containing capsules were able to keep a low coefficient of friction. The optimal performance is found for the coatings obtained at the lowest spraying temperature and velocity.

Combining spray nozzle simulators with meshes: characterization of rainfall intensity and drop properties

NASA Astrophysics Data System (ADS)

Carvalho, Sílvia C. P.; de Lima, João L. M. P.; de Lima, M. Isabel P.

2013-04-01

Rainfall simulators can be a powerful tool to increase our understanding of hydrological and geomorphological processes. Nevertheless, rainfall simulators' design and operation might be rather demanding, for achieving specific rainfall intensity distributions and drop characteristics. The pressurized simulators have some advantages over the non-pressurized simulators: drops do not rely on gravity to reach terminal velocity, but are sprayed out under pressure; pressurized simulators also yield a broad range of drop sizes in comparison with drop-formers simulators. The main purpose of this study was to explore in the laboratory the potential of combining spray nozzle simulators with meshes in order to change rainfall characteristics (rainfall intensity and diameters and fall speed of drops). Different types of spray nozzles were tested, such as single full-cone and multiple full-cone nozzles. The impact of the meshes on the simulated rain was studied by testing different materials (i.e. plastic and steel meshes), square apertures and wire thicknesses, and different vertical distances between the nozzle and the meshes underneath. The diameter and fall speed of the rain drops were measured using a Laser Precipitation Monitor (Thies Clima). The rainfall intensity range and coefficients of uniformity of the sprays and the drop size distribution, fall speed and kinetic energy were analysed. Results show that when meshes intercept drop trajectories the spatial distribution of rainfall intensity and the drop size distribution are affected. As the spray nozzles generate typically small drop sizes and narrow drop size distributions, meshes can be used to promote the formation of bigger drops and random their landing positions.

A Comparative Study of Cyclic Oxidation and Sulfates-Induced Hot Corrosion Behavior of Arc-Sprayed Ni-Cr-Ti Coatings at Moderate Temperatures

NASA Astrophysics Data System (ADS)

Guo, Wenmin; Wu, Yuping; Zhang, Jianfeng; Hong, Sheng; Chen, Liyan; Qin, Yujiao

2015-06-01

The cyclic oxidation and sulfates-induced hot corrosion behaviors of a Ni-43Cr-0.3Ti arc-sprayed coating at 550-750 °C were characterized and compared in this study. In general, all the oxidation and hot corrosion kinetic curves of the coating followed a parabolic law, i.e., the weight of the specimens showed a rapid growth initially and then reached the gradual state. However, the initial stage of the hot corrosion process was approximately two times longer than that of the oxidation process, indicating a longer preparation time required for the formation of a protective scale in the former process. At 650 °C, the parabolic rate constant for the hot corrosion was 7.2 × 10-12 g2/(cm4·s), approximately 1.7 times higher than that for the oxidation at the same temperature. The lower parabolic rate constant for the oxidation was mainly attributed to the formation of a protective oxide scale on the surface of corroded specimens, which was composed of a mixture of NiO, Cr2O3, and NiCr2O4. However, as the liquid molten salts emerged during the hot corrosion, these protective oxides would be dissolved and the coating was corrupted acceleratedly.

Biological response of Sr-containing coating with various surface treatments on titanium substrate for medical applications

NASA Astrophysics Data System (ADS)

Yang, Shih-Ping; Lee, Tzer-Min; Lui, Truan-Sheng

2015-08-01

An implant requires a suitable surface to trigger osteointegration. The surface characteristics and chemical composition are important factors in this process. Plasma spraying and micro-arc oxidation can be used to fabricate rough and porous structures for medical applications. Strontium (Sr) has been shown to prevent osteoporosis in vitro and in vivo. However, few scientists have evaluated the biological response of Sr-containing coatings on different surface treatments. In this study, a sand-blasted (SB) surface (as the control), plasma-sprayed hydroxyapatite (HA) and Sr-substituted HA coatings (HAPS and SrHAPS, respectively), calcium phosphate and Sr-containing calcium phosphate micro-arc oxidation surface (CPM and SrCPM, respectively) were analyzed in terms of human osteoblastic cell (MG63) response. Sr was confirmed to be incorporated into the surface. SrHAPS and SrCPM specimens had higher cell responses than those of the HAPS and CPM groups, respectively. The cells cultured on SrCPM and SrHAPS specimens exhibited high proliferation and differentiation. However, CPM and SrCPM specimens stimulated more ECM-like structures than other specimens. The results show that Sr-containing coatings have good characteristics that enhance cell response. The SrCPM coating is a suitable implant surface treatment for clinical applications.

Automated Welding System

NASA Technical Reports Server (NTRS)

Bayless, E. O.; Lawless, K. G.; Kurgan, C.; Nunes, A. C.; Graham, B. F.; Hoffman, D.; Jones, C. S.; Shepard, R.

1993-01-01

Fully automated variable-polarity plasma arc VPPA welding system developed at Marshall Space Flight Center. System eliminates defects caused by human error. Integrates many sensors with mathematical model of the weld and computer-controlled welding equipment. Sensors provide real-time information on geometry of weld bead, location of weld joint, and wire-feed entry. Mathematical model relates geometry of weld to critical parameters of welding process.

Strategic Alliances: Making a Difference One Warfighter At a Time

DTIC Science & Technology

2011-03-12

Prototype Integration Planning Machining / CNC / Metals Welding Assembly / Paint Integration •Field-Experienced Veterans •Component, Subsystems...Wiring Harness •CAD/CAM CNC Programming •Quick reaction of parts - CNC , Lathes, Mills, Water Jet/Laser Cutting Design •Mechanical, Electrical...DEFORMATION RESISTANCE WELDING • Tubular Structural welding, Light weight structures COMBINED PLASMA -MIG ARC WELDING • Faster than any other

Laser-Arc Hybrid Welding of Dissimilar Titanium Alloy and Stainless Steel Using Copper Wire

NASA Astrophysics Data System (ADS)

Gao, Ming; Chen, Cong; Wang, Lei; Wang, Zemin; Zeng, Xiaoyan

2015-05-01

Laser-arc hybrid welding with Cu3Si filler wire was employed to join dissimilar Ti6Al4V titanium alloy and AISI316 stainless steel (316SS). The effects of welding parameters on bead shape, microstructure, mechanical properties, and fracture behavior were investigated in detail. The results show that cross-weld tensile strength of the joints is up to 212 MPa. In the joint, obvious nonuniformity of the microstructure is found in the fusion zone (FZ) and at the interfaces from the top to the bottom, which could be improved by increasing heat input. For the homogeneous joint, the FZ is characterized by Fe67- x Si x Ti33 dendrites spreading on α-Cu matrix, and the two interfaces of 316SS/FZ and FZ/Ti6Al4V are characterized by a bamboo-like 316SS layer and a CuTi2 layer, respectively. All the tensile samples fractured in the hardest CuTi2 layer at Ti6Al4V side of the joints. The fracture surface is characterized by river pattern revealing brittle cleavage fracture. The bead formation mechanisms were discussed according to the melt flow and the thermodynamic calculation.

Wire Arc Additive Manufacturing of AZ31 Magnesium Alloy: Grain Refinement by Adjusting Pulse Frequency

PubMed Central

Guo, Jing; Zhou, Yong; Liu, Changmeng; Wu, Qianru; Chen, Xianping; Lu, Jiping

2016-01-01

Wire arc additive manufacturing (WAAM) offers a potential approach to fabricate large-scale magnesium alloy components with low cost and high efficiency, although this topic is yet to be reported in literature. In this study, WAAM is preliminarily applied to fabricate AZ31 magnesium. Fully dense AZ31 magnesium alloy components are successfully obtained. Meanwhile, to refine grains and obtain good mechanical properties, the effects of pulse frequency (1, 2, 5, 10, 100, and 500 Hz) on the macrostructure, microstructure and tensile properties are investigated. The results indicate that pulse frequency can result in the change of weld pool oscillations and cooling rate. This further leads to the change of the grain size, grain shape, as well as the tensile properties. Meanwhile, due to the resonance of the weld pool at 5 Hz and 10 Hz, the samples have poor geometry accuracy but contain finer equiaxed grains (21 μm) and exhibit higher ultimate tensile strength (260 MPa) and yield strength (102 MPa), which are similar to those of the forged AZ31 alloy. Moreover, the elongation of all samples is above 23%. PMID:28773944

Control of exposure to hexavalent chromium and ozone in gas metal arc welding of stainless steels by use of a secondary shield gas.

PubMed

Dennis, John H; French, Michael J; Hewitt, Peter J; Mortazavi, Seyed B; Redding, Christopher A J

2002-01-01

Previous work has demonstrated that the shield gas composition in gas metal arc welding can have a considerable effect on hexavalent chromium [Cr(VI)] concentration in the fume and on ozone concentrations near the arc. Normally a single shield gas is used. This paper describes a double shroud torch that allows used of concentric shield gases of different compositions. A solid stainless steel wire was used for welding. The double shroud torch used secondary shield gases containing small amounts of the reducing agents NO and C2H4. The Cr(VI) concentration in the fume and ozone concentration at a fixed point relative to the arc were measured and compared with results when using a single shield gas. Use of the reducing agents in secondary shielding using the double shroud torch was found to offer advantages for ozone concentration reduction compared with use in a conventional torch, but this was not found to be an advantage for reducing Cr(VI) concentrations.

Variable polarity plasma arc welding on the Space Shuttle external tank

NASA Technical Reports Server (NTRS)

Nunes, A. C., Jr.; Bayless, E. O., Jr.; Jones, C. S., III; Munafo, P. M.; Biddle, A. P.; Wilson, W. A.

1984-01-01

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.

Optimization of hybrid laser arc welding of 42CrMo steel to suppress pore formation

NASA Astrophysics Data System (ADS)

Zhang, Yan; Chen, Genyu; Mao, Shuai; Zhou, Cong; Chen, Fei

2017-06-01

The hybrid laser arc welding (HLAW) of 42CrMo quenched and tempered steel was conducted. The effect of the processing parameters, such as the relative positions of the laser and the arc, the shielding gas flow rate, the defocusing distance, the laser power, the wire feed rate and the welding speed, on the pore formation was analyzed, the morphological characteristics of the pores were analyzed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results showed that the majority of the pores were invasive. The pores formed at the leading a laser (LA) welding process were fewer than those at the leading a arc (AL) welding process. Increasing the shielding gas flow rate could also facilitate the reduction of pores. The laser power and the welding speed were two key process parameters to reduce the pores. The flow of the molten pool, the weld cooling rate and the pore escaping rate as a result of different parameters could all affect pore formation. An ideal pore-free weld was obtained for the optimal welding process parameters.

Sliding bubbles on a hot horizontal wire in a subcooled bath

NASA Astrophysics Data System (ADS)

Duchesne, Alexis; Dubois, Charles; Caps, Hervé

2015-11-01

When a wire is heated up to the boiling point in a liquid bath some bubbles will nucleate on the wire surface. Traditional nucleate boiling theory predicts that bubbles generate from active nucleate site, grow up and depart from the heating surface due to buoyancy and inertia. However, an alternative scenario is presented in the literature for a subcooled bath: bubbles slide along the horizontal wire before departing. New experiments were performed by using a constantan wire and different liquids, varying the injected power. Silicone oil, water and even liquid nitrogen were tested in order to vary wetting conditions, liquid viscosities and surface tensions. We explored the influence of the wire diameter and of the subcooled bath temperature. We observed, of course, sliding motion, but also a wide range of behaviors from bubbles clustering to film boiling. We noticed that bubbles could change moving sense, especially when encountering with another bubble. The bubble speed is carefully measured and can reach more than 100 mm/s for a millimetric bubble. We investigated the dependence of the speed on the different parameters and found that this speed is, for a given configuration, quite independent of the injected power. We understand these phenomena in terms of Marangoni effects. This project has been financially supported by ARC SuperCool contract of the University of Liège.

Al2O3-ZrO2 Finely Structured Multilayer Architectures from Suspension Plasma Spraying

NASA Astrophysics Data System (ADS)

Tingaud, Olivier; Montavon, Ghislain; Denoirjean, Alain; Coudert, Jean-François; Rat, Vincent; Fauchais, Pierre

2010-01-01

Suspension plasma spraying (SPS) is an alternative to conventional atmospheric plasma spraying (APS) aiming at manufacturing thinner layers (i.e., 10-100 μm) due to the specific size of the feedstock particles, from a few tens of nanometers to a few micrometers. The staking of lamellae and particles, which present a diameter ranging from 0.1 to 2.0 μm and an average thickness from 20 to 300 nm, permits to manufacture finely structured layers. Moreover, it appears as a versatile process able to manufacture different coating architectures according to the operating parameters (suspension properties, injection configuration, plasma properties, spray distance, torch scan velocity, scanning step, etc.). However, the different parameters controlling the properties of the coating, and their interdependences, are not yet fully identified. Thus, the aim of this paper is, on the one hand, to better understand the influence of operating parameters on the coating manufacturing mechanisms (in particular, the plasma gas mixture effect) and, on the other hand, to produce Al2O3-ZrO2 finely structured layers with large varieties of architectures. For this purpose, a simple theoretical model was used to describe the plasma torch operating conditions at the nozzle exit, based on experimental data (mass enthalpy, arc current intensity, thermophysical properties of plasma forming gases, etc.) and the influences of the spray parameters were determined by mean of the study of sizes and shapes of spray beads. The results enabled then to reach a better understanding of involved phenomena and their interactions on the final coating architectures permitting to manufacture several types of microstructures.

Spray-Deposited Large-Area Copper Nanowire Transparent Conductive Electrodes and Their Uses for Touch Screen Applications.

PubMed

Chu, Hsun-Chen; Chang, Yen-Chen; Lin, Yow; Chang, Shu-Hao; Chang, Wei-Chung; Li, Guo-An; Tuan, Hsing-Yu

2016-05-25

Large-area conducting transparent conducting electrodes (TCEs) were prepared by a fast, scalable, and low-cost spray deposition of copper nanowire (CuNW) dispersions. Thin, long, and pure copper nanowires were obtained via the seed-mediated growth in an organic solvent-based synthesis. The mean length and diameter of nanowires are, respectively, 37.7 μm and 46 nm, corresponding to a high-mean-aspect ratio of 790. These wires were spray-deposited onto a glass substrate to form a nanowire conducting network which function as a TCE. CuNW TCEs exhibit high-transparency and high-conductivity since their relatively long lengths are advantageous in lowering in the sheet resistance. For example, a 2 × 2 cm(2) transparent nanowire electrode exhibits transmittance of T = 90% with a sheet resistance as low as 52.7 Ω sq(-1). Large-area sizes (>50 cm(2)) of CuNW TCEs were also prepared by the spray coating method and assembled as resistive touch screens that can be integrated with a variety of devices, including LED lighting array, a computer, electric motors, and audio electronic devices, showing the capability to make diverse sizes and functionalities of CuNW TCEs by the reported method.

An evaluation of welding processes to reduce hexavalent chromium exposures and reduce costs by using better welding techniques.

PubMed

Keane, Michael J

2014-01-01

A group of stainless steel arc welding processes was compared for emission rates of fume and hexavalent chromium, and costs per meter length of weld. The objective was to identify those with minimal emissions and also compare relative labor and consumables costs. The selection included flux-cored arc welding (FCAW), shielded-metal arc welding (SMAW), and multiple gas metal arc welding (GMAW) processes. Using a conical chamber, fumes were collected, and fume generation rates and hexavalent chromium (Cr(6+)) were measured. GMAW processes used were short-circuit (SC) and pulsed-spray modes. Flux-cored welding used gas shielding. Costs were estimated per meter of a 6.3-mm thick horizontal butt weld. Emission rates of Cr(6+) were lowest for GMAW processes and highest for SMAW; several GMAW processes had less than 2% of the SMAW generation rate. Labor and consumable costs for the processes studied were again highest for SMAW, with those of several GMAW types about half that cost. The results show that use of any of the GMAW processes (and flux-cored welding) could substantially reduce fume and Cr(6+) emissions, and greatly reduce costs relative to SMAW.

An Evaluation of Welding Processes to Reduce Hexavalent Chromium Exposures and Reduce Costs by Using Better Welding Techniques

PubMed Central

Keane, Michael J

2014-01-01

A group of stainless steel arc welding processes was compared for emission rates of fume and hexavalent chromium, and costs per meter length of weld. The objective was to identify those with minimal emissions and also compare relative labor and consumables costs. The selection included flux-cored arc welding (FCAW), shielded-metal arc welding (SMAW), and multiple gas metal arc welding (GMAW) processes. Using a conical chamber, fumes were collected, and fume generation rates and hexavalent chromium (Cr6+) were measured. GMAW processes used were short-circuit (SC) and pulsed-spray modes. Flux-cored welding used gas shielding. Costs were estimated per meter of a 6.3-mm thick horizontal butt weld. Emission rates of Cr6+ were lowest for GMAW processes and highest for SMAW; several GMAW processes had less than 2% of the SMAW generation rate. Labor and consumable costs for the processes studied were again highest for SMAW, with those of several GMAW types about half that cost. The results show that use of any of the GMAW processes (and flux-cored welding) could substantially reduce fume and Cr6+ emissions, and greatly reduce costs relative to SMAW. PMID:25574138

Emissions of chromium (VI) from arc welding.

PubMed

Heung, William; Yun, Myoung-Jin; Chang, Daniel P Y; Green, Peter G; Halm, Chris

2007-02-01

The presence of Cr in the +6 oxidation state (Cr[VI]) is still observed in ambient air samples in California despite steps taken to reduce emissions from plating operations. One known source of emission of Cr(VI) is welding, especially with high Cr-content materials, such as stainless steels. An experimental effort was undertaken to expand and update Cr(VI) emission factors by conducting tests on four types of arc-welding operations: gas-metal arc welding (GMAW), shielded metal arc welding (SMAW), fluxcore arc welding, and pulsed GMAW. Standard American Welding Society hood results were compared with a total enclosure method that permitted isokinetic sampling for particle size-cut measurement, as well as total collection of the aerosol. The fraction of Cr(VI) emitted per unit mass of Cr electrode consumed was determined. Consistent with AP-42 data, initial results indicate that a significant fraction of the total Cr in the aerosol is in the +6 oxidation state. The fraction of Cr(VI) and total aerosol mass produced by the different arc welding methods varies with the type of welding process used. Self-shielded electrodes that do not use a shield gas, for example, SMAW, produce greater amounts of Cr(VI) per unit mass of electrode consumed. The formation of Cr(VI) from standard electrode wires used for welding mild steel was below the method detection limit after eliminating an artifact in the analytical method used.

Internal fixation of displaced inferior pole of the patella fractures using vertical wiring augmented with Krachow suturing.

PubMed

Oh, Hyoung-Keun; Choo, Suk-Kyu; Kim, Ji-Wan; Lee, Mark

2015-12-01

We present the surgical technique of separate vertical wiring for displaced inferior pole fractures of the patella combined with Krachow suture and report the surgical outcomes. Between September 2007 to May 2012, 11 consecutive patients (mean age, 54.6 years) with inferior pole fractures of the patella (AO/OTA 34-A1) were retrospectively enrolled in this study. Through longitudinal incision, all patients underwent open reduction and internal fixation by separate vertical wiring combined with Krackow suture. The range of motion, loss of fixation, and Bostman score were primary outcome measures. The union time was 10 weeks after surgery on average (range: 8-12). No patient had nonunion, loss of reduction and wire breakage. There was no case of wound problem and irritation from the implant. At final follow-up, the average range of motion arc was 129.4° (range: 120-140). The mean Bostman score at last follow-up was 29.6 points (range: 28-30) and graded excellent in all cases. Separate vertical wiring combined with Krackow suture for inferior pole fractures of the patella is a useful technique that is easy to perform and can provide stable fixation with excellent results in knee function. Copyright © 2015 Elsevier Ltd. All rights reserved.

Generation rate of carbon monoxide from CO2 arc welding.

PubMed

Ojima, Jun

2013-01-01

CO poisoning has been a serious industrial hazard in Japanese workplaces. Although incomplete combustion is the major cause of CO generation, there is a risk of CO poisoning during some welding operations. The aim of the present study was to evaluate the generation rate of CO from CO2 arc welding under controlled laboratory conditions and estimate the ventilation requirements for the prevention of CO poisoning. Bead on plate welding was carried out with an automatic welding robot on a rolled steel base metal under several conditions. The concentration of emitted CO from the welding was measured by a real-time CO monitor in a well-ventilated laboratory that was free from ambient CO contamination. The generation rate of CO was obtained from the three measurements-the flow rate of the welding exhaust gas, CO concentration in the exhaust gas and the arcing time. Then the ventilation requirement to prevent CO poisoning was calculated. The generation rate of CO was found to be 386-883 ml/min with a solid wire and 331-1,293 ml/min with a flux cored wire respectively. It was found that the CO concentration in a room would be maintained theoretically below the OSHA PEL (50 ppm) providing the ventilation rate in the room was 6.6-25.9 m3/min. The actual ventilation requirement was then estimated to be 6.6-259 m3/min considering incomplete mixing. In order to prevent CO poisoning, some countermeasures against gaseous emission as well as welding fumes should be taken eagerly.

Characterizing Suspension Plasma Spray Coating Formation Dynamics through Curvature Measurements

NASA Astrophysics Data System (ADS)

Chidambaram Seshadri, Ramachandran; Dwivedi, Gopal; Viswanathan, Vaishak; Sampath, Sanjay

2016-12-01

Suspension plasma spraying (SPS) enables the production of variety of microstructures with unique mechanical and thermal properties. In SPS, a liquid carrier (ethanol/water) is used to transport the sub-micrometric feedstock into the plasma jet. Considering complex deposition dynamics of SPS technique, there is a need to better understand the relationships among spray conditions, ensuing particle behavior, deposition stress evolution and resultant properties. In this study, submicron yttria-stabilized zirconia particles suspended in ethanol were sprayed using a cascaded arc plasma torch. The stresses generated during the deposition of the layers (termed evolving stress) were monitored via the change in curvature of the substrate measured using an in situ measurement apparatus. Depending on the deposition conditions, coating microstructures ranged from feathery porous to dense/cracked deposits. The evolving stresses and modulus were correlated with the observed microstructures and visualized via process maps. Post-deposition bi-layer curvature measurement via low temperature thermal cycling was carried out to quantify the thermo-elastic response of different coatings. Lastly, preliminary data on furnace cycle durability of different coating microstructures were evaluated. This integrated study involving in situ diagnostics and ex situ characterization along with process maps provides a framework to describe coating formation mechanisms, process parametrics and microstructure description.

Development of a new generation of high-temperature composite materials

NASA Technical Reports Server (NTRS)

Brindley, P. K.

1990-01-01

Intermetallic matrix composites proposed to meet advanced aeropropulsion requirements are discussed. The powder metallurgy fabrication process currently being used to produce these intermetallic matrix composites will be presented, as will properties of one such composite, SiC/Ti3Al+Nb. In addition, the direction of future research will be outlined, including plans for enhanced fabrication of intermetallic composites by the arc-spray technique and fiber development by the floating-zone process.

Application of welding science to welding engineering: A lumped parameter gas metal arc welding dynamic process model

DOE Office of Scientific and Technical Information (OSTI.GOV)

Murray, P.E.; Smartt, H.B.; Johnson, J.A.

1997-12-31

We develop a model of the depth of penetration of the weld pool in gas metal arc welding (GMAW) which demonstrates interaction between the arc, filler wire and weld pool. This model is motivated by the observations of Essers and Walter which suggest a relationship between droplet momentum and penetration depth. A model of gas metal arc welding was augmented to include an improved model of mass transfer and a simple model of accelerating droplets in a plasma jet to obtain the mass and momentum of impinging droplets. The force of the droplets and depth of penetration is correlated bymore » a dimensionless linear relation used to predict weld pool depth for a range of values of arc power and contact tip to workpiece distance. Model accuracy is examined by comparing theoretical predictions and experimental measurements of the pool depth obtained from bead on plate welds of carbon steel in an argon rich shielding gas. Moreover, theoretical predictions of pool depth are compared to the results obtained from the heat conduction model due to Christensen et al. which suggest that in some cases the momentum of impinging droplets is a better indicator of the depth of the weld pool and the presence of a deep, narrow penetration.« less

From the Scale Model of the Sky to the Armillary Sphere

ERIC Educational Resources Information Center

Gangui, Alejandro; Casazza, Roberto; Paex, Carlos

2014-01-01

It is customary to employ a semi-spherical scale model to describe the apparent path of the Sun across the sky, whether it be its diurnal motion or its variation throughout the year. A flat surface and three bent semi-rigid wires (representing the three solar arcs during solstices and equinoxes) will do the job. On the other hand, since very early…

Investigation of plasma arc welding as a method for the additive manufacturing of titanium-(6)aluminum-(4)vanadium alloy components

NASA Astrophysics Data System (ADS)

Stavinoha, Joe N.

The process of producing near net-shape components by material deposition is known as additive manufacturing. All additive manufacturing processes are based on the addition of material with the main driving forces being cost reduction and flexibility in both manufacturing and product design. With wire metal deposition, metal is deposited as beads side-by-side and layer-by-layer in a desired pattern to build a complete component or add features on a part. There are minimal waste products, low consumables, and an efficient use of energy and feedstock associated with additive manufacturing processes. Titanium and titanium alloys are useful engineering materials that possess an extraordinary combination of properties. Some of the properties that make titanium advantageous for structural applications are its high strength-to-weight ratio, low density, low coefficient of thermal expansion, and good corrosion resistance. The most commonly used titanium alloy, Ti-6Al-4V, is typically used in aerospace applications, pressure vessels, aircraft gas turbine disks, cases and compressor blades, and surgical implants. Because of the high material prices associated with titanium alloys, the production of near net-shape components by additive manufacturing is an attractive option for the manufacturing of Ti-6Al-4V alloy components. In this thesis, the manufacturing of cylindrical Ti-6Al-4V alloy specimens by wire metal deposition utilizing the plasma arc welding process was demonstrated. Plasma arc welding is a cost effective additive manufacturing technique when compared to other current additive manufacturing methods such as laser beam welding and electron beam welding. Plasma arc welding is considered a high-energy-density welding processes which is desirable for the successful welding of titanium. Metal deposition was performed using a constant current plasma arc welding power supply, flow-purged welding chamber, argon shielding and orifice gas, ERTi-5 filler metal, and Ti-6Al-4V alloy substrates. Cylindrical weld metal deposits were built by employing an automatic wire feeder, turntable positioner, and vertical torch positioner. A total of four cylindrical weld metal specimens were built with various combinations of essential plasma arc welding process parameters. The temperature of the weld metal deposit was taken with a thermocouple after allowing a specified amount of time to pass before depositing the next weld track. An analytical heat flow model was created that estimated the temperature of the weld metal deposit in relation to the number of tracks deposited. The analytical heat flow model was adjusted to match the experimental data that was obtained and revealed that the rate of production could be increased if the rate of thermal energy losses from the deposit were increased. Cross-sections of the weld metal deposits were examined to observe the effects of thermal energy input on the weld metal macrostructure, microstructure, and grain size. Results from the metallographic inspections revealed an increase in grain size and coarsening of the structure as the number of weld tracks in the deposit increased.

Fused Silica Surface Coating for a Flexible Silica Mat Insulation System

NASA Technical Reports Server (NTRS)

Rhodes, W. H.

1973-01-01

Fused silica insulation coatings have been developed for application to a flexible mat insulation system. Based on crystalline phase nucleation and growth kinetics, a 99+% SiO2 glass was selected as the base composition. A coating was developed that incorporated the high emissivity phase NiCr2O4 as a two phase coating with goals of high emittance and minimum change in thermal expansion. A second major coating classification has a plasma sprayed emittance coating over a sealed pure amorphous SiO2 layer. A third area of development centered on extremely thin amorphous SiO2 coatings deposited by chemical vapor deposition. The coating characterization studies presented are mechanical testing of thin specimens extracted from the coatings, cyclic arc exposures, and emittance measurements before and after arc exposures.

SnS2 Thin Film Deposition by Spray Pyrolysis

NASA Astrophysics Data System (ADS)

Jaber, Abdallah Yahia; Alamri, Saleh Noaiman; Aida, Mohammed Salah

2012-06-01

Tin disulfide (SnS2) thin films have been synthesized using a simplified spray pyrolysis technique using a perfume atomizer. The films were deposited using two different solutions prepared by the dilution of SnCl2 and thiourea in distilled water and in methanol. The obtained films have a microcrystalline structure. The film deposited using methanol as the solvent is nearly stochiometric SnS2 with a spinel phase having a (001) preferential orientation. The film prepared with an aqueous solution is Sn-rich. Scanning electronic microscopy (SEM) images reveal that the film deposited with the aqueous solution is rough and is formed with large wires. However, the film deposited with methanol is dense and smooth. Conductivity measurements indicate that the aqueous solution leads to an n-type semiconductor, while methanol leads to a p-type semiconductor.

Carbon nanotube and graphene nanoribbon-coated conductive Kevlar fibers.

PubMed

Xiang, Changsheng; Lu, Wei; Zhu, Yu; Sun, Zhengzong; Yan, Zheng; Hwang, Chi-Chau; Tour, James M

2012-01-01

Conductive carbon material-coated Kevlar fibers were fabricated through layer-by-layer spray coating. Polyurethane was used as the interlayer between the Kevlar fiber and carbon materials to bind the carbon materials to the Kevlar fiber. Strongly adhering single-walled carbon nanotube coatings yielded a durable conductivity of 65 S/cm without significant mechanical degradation. In addition, the properties remained stable after bending or water washing cycles. The coated fibers were analyzed using scanning electron microcopy and a knot test. The as-produced fiber had a knot efficiency of 23%, which is more than four times higher than that of carbon fibers. The spray-coating of graphene nanoribbons onto Kevlar fibers was also investigated. These flexible coated-Kevlar fibers have the potential to be used for conductive wires in wearable electronics and battery-heated armors. © 2011 American Chemical Society

An interactive modeling program for the generation of planar polygons for boundary type solids representations of wire frame models

NASA Technical Reports Server (NTRS)

Ozsoy, T.; Ochs, J. B.

1984-01-01

The development of a general link between three dimensional wire frame models and rigid solid models is discussed. An interactive computer graphics program was developed to serve as a front end to an algorithm (COSMIC Program No. ARC-11446) which offers a general solution to the hidden line problem where the input data is either line segments of n-sided planar polygons of the most general type with internal boundaries. The program provides a general interface to CAD/CAM data bases and is implemented for models created on the Unigraphics VAX 11/780-based CAD/CAM systems with the display software written for DEC's VS11 color graphics devices.

Control of surface defects on plasma-MIG hybrid welds in cryogenic aluminum alloys

NASA Astrophysics Data System (ADS)

Lee, Hee-Keun; Chun, Kwang-San; Park, Sang-Hyeon; Kang, Chung-Yun

2015-07-01

Lately, high production rate welding processes for Al alloys, which are used as LNG FPSO cargo containment system material, have been developed to overcome the limit of installation and high rework rates. In particular, plasma-metal inert gas (MIG) hybrid (PMH) welding can be used to obtain a higher deposition rate and lower porosity, while facilitating a cleaning effect by preheating and post heating the wire and the base metal. However, an asymmetric undercut and a black-colored deposit are created on the surface of PMH weld in Al alloys. For controlling the surface defect formation, the wire feeding speed and nozzle diameter in the PMH weld was investigated through arc phenomena with high-speed imaging and metallurgical analysis.

Effects of space plasma discharge on the performance of large antenna structures in low Earth orbit

NASA Technical Reports Server (NTRS)

Blume, Hans-Juergen C.

1987-01-01

The anomalous plasma around spacecrafts in low Earth orbit represents the coma of an artificial comet. The plasma discharge is caused by an energetic disturbance of charged particles which were formerly in a state of equilibrium. The plasma can effect the passive and active radio frequency operation of large space antennas by inducing corona discharge or strong arcing in the antenna feeds. One such large space antenna is the 15-meter hoop column antenna which consists of a mesh membrane material (tricot knitted gold plated wire) reflector and carbon fiber tension cords. The atomic oxygen in the plasma discharge state can force the wire base metal particles through the gold lattice and oxydize the metal particles to build a Schottky-barrier contact at the point where the wires meet. This effect can cause strong deviations in the reflector performance in terms of antenna pattern and losses. Also, the carbon-fiber cords can experience a strength reduction of 30 percent over a 40-hour exposure time.

Report of the Seasat Failure Review Board

NASA Technical Reports Server (NTRS)

1993-01-01

The Seasat spacecraft failed on October 9, 1978, after satisfactory operation in orbit for 105 days, as a result of a loss of electrical power in the Agena bus that was used as a part of the spacecraft. The loss of power was caused by a massive and progressive short in one of the slip ring assemblies that was used to connect the rotating solar arrays into the power subsystem. The most likely cause of this short was the initiation of an arc between adjacent slip ring brush assemblies. The triggering mechanism of this arc could have been either a wire-to-brush assembly contact, a brush-to-brush contact, or a momentary short caused by a contaminant that bridged internal components of opposite electrical polarity.

Method of forming a leak proof plasma sprayed interconnection layer on an electrode of an electrochemical cell

DOEpatents

Kuo, Lewis J. H.; Vora, Shailesh D.

1995-01-01

A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an electrode structure of an electrochemical cell by: (A) providing an electrode structure; (B) forming on a selected portion of the electrode surface, an interconnection layer having the general formula La.sub.1-x M.sub.x Cr.sub.1-y N.sub.y O.sub.3, where M is a dopant selected from the group of Ca, Sr, Ba, and mixtures thereof, and where N is a dopant selected from the group of Mg, Co, Ni, Al, and mixtures thereof, and where x and y are each independently about 0.075-0.25, by thermally spraying, preferably plasma arc spraying, a flux added interconnection spray powder, preferably agglomerated, the flux added powder comprising flux particles, preferably including dopant, preferably (CaO).sub.12. (Al.sub.2 O.sub.3).sub.7 flux particles including Ca and Al dopant, and LaCrO.sub.3 interconnection particles, preferably undoped LaCrO.sub.3, to form a dense and substantially gas-tight interconnection material bonded to the electrode structure by a single plasma spraying step; and, (C) heat treating the interconnection layer at from about 1200.degree. to 1350.degree. C. to further densify and heal the micro-cracks and macro-cracks of the thermally sprayed interconnection layer. The result is a substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode structure. The electrode structure can be an air electrode, and a solid electrolyte layer can be applied to the unselected portion of the air electrode, and further a fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell for generation of electrical power.

Method of forming a leak proof plasma sprayed interconnection layer on an electrode of an electrochemical cell

DOEpatents

Kuo, L.J.H.; Vora, S.D.

1995-02-21

A dense, substantially gas-tight, electrically conductive interconnection layer is formed on an electrode structure of an electrochemical cell by: (A) providing an electrode structure; (B) forming on a selected portion of the electrode surface, an interconnection layer having the general formula La{sub 1{minus}x}M{sub x}Cr{sub 1{minus}y}N{sub y}O{sub 3}, where M is a dopant selected from the group of Ca, Sr, Ba, and mixtures thereof, and where N is a dopant selected from the group of Mg, Co, Ni, Al, and mixtures thereof, and where x and y are each independently about 0.075--0.25, by thermally spraying, preferably plasma arc spraying, a flux added interconnection spray powder, preferably agglomerated, the flux added powder comprising flux particles, preferably including dopant, preferably (CaO){sub 12}(Al{sub 2}O{sub 3}){sub 7} flux particles including Ca and Al dopant, and LaCrO{sub 3} interconnection particles, preferably undoped LaCrO{sub 3}, to form a dense and substantially gas-tight interconnection material bonded to the electrode structure by a single plasma spraying step; and (C) heat treating the interconnection layer at from about 1,200 to 1,350 C to further densify and heal the micro-cracks and macro-cracks of the thermally sprayed interconnection layer. The result is a substantially gas-tight, highly doped, electrically conductive interconnection material bonded to the electrode structure. The electrode structure can be an air electrode, and a solid electrolyte layer can be applied to the unselected portion of the air electrode, and further a fuel electrode can be applied to the solid electrolyte, to form an electrochemical cell for generation of electrical power. 4 figs.

Process characteristics of the combination of laser beam- and gas metal arc welding

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kalla, G.; Neuenhahn, J.; Koerber, C.

1994-12-31

In this presentation, experiences regarding the combination of laser beam-and gas metal arc welding are discussed. The combination of both techniques offers the possibility of using the specific advantages include the deep penetration effect and the concentrated heat input. Additionally, the gas metal arc welding (GMAW) process is characterized by several advantages, such as high thermal efficiency and good gap-bridging ability. Beyond these characteristics, the combination leads to additional advantages concerning process, technique, and quality. Improvement of seam quality and properties are of special note. Adaptation of the GMAW parameters reduces the hardness of the seam weld at increasing weldingmore » speed. This is possible by adapting the efficiency of metal deposition and by the suitable choice of wire material composition. Another advantage is an improvement of surface topology. The surface of the weld seam and the connection to the base material are very smooth. This leads to advantages with regard to the fatigue strength of the seam.« less

[Separate vertical wiring combined with tension band and Kirschner-wire plus cerclage wire in the treatment of displaced inferior pole fractures of the patella].

PubMed

Zhang, J; Jiang, X Y; Huang, X W

2016-06-18

To investigate the clinical efficacy and outcomes of two separate vertical wiring combined with tension band and Kirschner-wire plus cerclage wire in the treatment of displaced inferior pole fractures of the patella. From January 2013 to January 2015, 15 consecutive patients (mean age 54.5 years) with inferior pole fractures of the patella were retrospectively included in this study. All the patients underwent open reduction and internal fixation by separate vertical wiring combined with tension band and Kirschner-wire plus cerclage wire through longitudinal incision, 4.5 d (range: 3.1-5.9 d) after initial injury. A safety check for early knee range of motion was performed before wound closure. The complications including infection, nonunion, loss of fixation and any wire breakage or irritation from implant were recorded. Anteroposterior and lateral views of the knee joint obtained during the follow-up were used to assess bony union based on the time when the fracture line disappeared. At the time of the final outpatient follow up, functional evaluation of the knee joint was conducted by Bostman system. The follow-up time was 13.1 months (range: 12-19 months) after surgery on average, immediate motion without immobilization in all the cases was allowed and there was no case of reduction loss of the fracture and wire breakage. There was no case of irritation from the implant. At the final follow-up, the average range of motion (ROM) arc was 126.7° (range: 115°-140°), the average ROM lag versus contralateral healthy leg was 10.3° (range: 0°-35°). The mean Bostman score at the last follow-up was 28.9 (range: 27-30), and graded excellent in most cases. Two separate vertical wiring is an easy and effective method to reduce the displaced inferior pole fracture of patella. Augmentation of separate vertical wiring with tension band and Kirschner-wire plus cerclage wire in these patients provides enough strength to protected the early exercise of the knee joint and uneventful healing. By this surgical treatment, excellent results in knee function can be expected for cases of displaced inferior pole fractures of the patella.

Thermophysical Properties of Matter - The TPRC Data Series. Volume 3. Thermal Conductivity - Nonmetallic Liquids and Gases

DTIC Science & Technology

1970-01-01

design and experimentation. I. The Shock- Tube Method Smiley [546] introduced the use of shock waves...one of the greatest disadvantages of this technique. Both the unique adaptability of the shock tube method for high -temperature measurement of...Line-Source Flow Method H. The Hot-Wire Thermal Diffusion Column Method I. The Shock- Tube Method J. The Arc Method K. The Ultrasonic Method .

Weldability of extruded aluminum-alumina composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gedeon, S.A.; Lane, C.; Altshuller, B.

1994-12-31

Acceptable procedure were developed for welding the following types of aluminum particle-reinforced aluminum: 6061/Al{sub 2}O{sub 3}/10p-T6, 6061/Al{sub x}/O{sub 3}20p-T6, and 7005Al{sub 2}O{sub 3}/10p-T6,. Automated and manual procedures were developed and using both gas tungsten arc welding (GTAW), with a cold wire feed, and gas metal arc welding (GMAW). The effect of welding procedures on porosity, reinforcing particulate distribution, and mechanical properties was determined. Postweld heat treatment and microhardness testing were used to understand the effect of the welded microstructure on the strength and ductility of the joint. Fracture surfaces and transverse microsections of mechanical test specimens were examined to determinemore » the origins and mechanisms of failure. Cleanliness of the joint and weld wire were found to be essential to eliminate porosity. Based on these experimentally determined data, general guidelines for welding aluminum oxide particle-reinforced aluminum composites are proposed. Discussion includes proper selection of weld joint geometry, filler metals, travel speed, voltage, and current ranges. These parameters are compared to those used in an actual production environment for composite products. Distinctions between welding these composites and others produced via powder metallurgy or with silicon carbide reinforcements are also discussed.« less

Development of Novel Fe-Based Coating Systems for Internal Combustion Engines

NASA Astrophysics Data System (ADS)

Bobzin, K.; Öte, M.; Königstein, T.; Dröder, K.; Hoffmeister, H.-W.; Mahlfeld, G.; Schläfer, T.

2018-04-01

Nowadays, combustion engines are the most common way to power vehicles. Thereby, losses occur due to cooling, exhaust gas and friction. With regard to frictional losses, highest potentials for optimization can be found in the tribological system of the inner surface of combustion chamber and piston ring. Besides friction, corrosive stress increases, e.g., due to utilization of exhaust gas recovery. In order to save energy, reduce emissions and enhance the life span of combustion engines, the demand for innovative coating material systems, especially for the inner surface of combustion chamber, increases. This study focuses on the development of innovative iron-based coating materials for the combustion chamber. As a first step, the plasma transferred wire arc and rotating single wire arc (RSW) technologies were compared using 0.8% C-steel as a reference. Subsequently, RSW was used for coating deposition using an innovative iron-based feedstock material. In order to improve wear and corrosion resistance, boron and chromium were added to the feedstock material. After deposition, different honing topographies were manufactured and compared under tribological load. Furthermore, electrochemical corrosion tests were conducted using an electrolyte simulating the exhaust gas concentrate. Especially with regard to corrosion, the novel coating system FeCrBMn showed promising results.

Weldability of Weldalite (tm) 049 with and without TiB2 reinforcement

NASA Technical Reports Server (NTRS)

1991-01-01

The effects are assessed of TiB2 reinforcement and parent alloy Li content on the weldability of Weldalite (tm) 049 type alloys. Welding trials were performed using either AC or DC polarity gas tungsten arc (GTA) welding according to described procedures. The welding was performed under conditions of high restraint on 5 cm (2 in) wide x 25.4 cm (10 in) long plates machined from the 0.952 cm (0.375 in) extruded bar parallel to the extrusion direction. A 37.5 deg bevel was machined on the center edge of the extruded bar. Cut rod filler wire was machined from three alloys, and one commercially available 2319 filler wire was also used. The preliminary assessment of the weldability revealed no propensity for hot cracking under conditions of high restraint. This result is significant, because hot cracking has been reported for all other leading aluminum lithium alloys welded with certain conventional filler alloys. The strengths for Weldalite parent welded with parent filler obtained were higher than those for alloys used in launch systems, such as 2219 and 2014 welded with 2319 and 4043 fillers, respectively. Even higher values were obtained by variable polarity plasma arc welding (e.g., 54 ksi (372 MPa) mean tensile strength).

Radiographic research of the Bi plasma jet formed by the vacuum arc discharge

NASA Astrophysics Data System (ADS)

Artyomov, A. P.; Rousskikh, A. G.; Fedunin, A. V.; Chaikovsky, S. A.; Zhigalin, A. S.; Oreshkin, V. I.

2017-05-01

The results of experiments on a soft x-ray radiography (≈ 1-2 keV) of a bismuth plasma formed by the high-current vacuum arc discharge are represented. The plasma gun with the arc current ≈ 60 kA and the current rise time ≈ 7 μs was used to produce the Bi plasma jet. The compact pulsed radiograph XPG-1 (250 kA, 220 ns) with an X-pinch load consisting of four Mo wires with a diameter 25 μm was used as a source of the soft X-ray radiation. The X-ray backlighting images of the researched plasma jet and the Bi step-wedge with a step thickness of ≈ 100 nm were recorded simultaneously in the course of the experiment. A comparison of the plasma jet x-ray image with the current trace has enabled to estimate dependencies of the linear mass on the arc current. The experiments have shown that when the arc current density reaches ≈ 3·105 A/cm2, the evaporation rate of the electrode material reaches ≈ 100 μg/μs, that under the plasma velocity ≈ 0.5 cm/μs, provides a plasma jet linear mass ≈ 200 μg/cm. At a distance of ≈ 1-2 mm from the arc cathode surface, the sharp increase of the jet linear mass (up to ≈ 500 μg/cm) occurred.

Measurements of temperature and pressure fluctuations in the T prime 2 cryogenic wind tunnel

NASA Technical Reports Server (NTRS)

Blanchard, A.; Dor, J. B.; Breil, J. F.

1980-01-01

Cold wire measurement of temperature fluctuations were made in a DERAT T'2 induction powered cryogenic wind tunnel for 2 types of liquid nitrogen injectors. Thermal turbulence measured in the tranquilization chamber depends to a great extent on the injector used; for fine spray of nitrogen drops, this level of turbulence seemed completely acceptable. Fluctuations in static pressure taken from the walls of the vein by Kulite sensors showed that there was no increase in aerodynamic noise during cryogenic gusts.

Investigation of Hydrophobic Radomes for Microwave Landing System.

DTIC Science & Technology

1982-11-01

horizontal heating wires on the inside surface, and 2) a slotted waveguide unit (C-band waveguide, about 2 feet in length) covered with a Teflon shrink tube ...AZ) Fiberglass flat 1.5ft x 13ft NE sandwich (EL) Teflon shrink 1 in x 2 ft SW tubing (Field Mon.) 7 (8) Hydrophobic Coating for Antenna Weather...SURFACE PREPARATION 13 24 Mar 󈨖 Conolite Primer: Vellox S-048 Finish: Microfine FSD, 7 coats, sprayed 14 24 Mar 󈨖 Conolite Teflon film, C-TAPE-36

Study of electrochemical properties of thin film materials obtained using plasma technologies for production of electrodes for pacemakers

NASA Astrophysics Data System (ADS)

Obrezkov, O. I.; Vinogradov, V. P.; Krauz, V. I.; Mozgrin, D. V.; Guseva, I. A.; Andreev, E. S.; Zverev, A. A.; Starostin, A. L.

2016-09-01

Studies of thin film materials (TFM) as coatings of tips of pacemaker electrodes implanted into the human heart have been performed. TFM coatings were deposited in vacuum by arc magnetron discharge plasma, by pulsed discharge of “Plasma Focus”, and by electron beam evaporation. Simulation of electric charge transfer to the heart in physiological blood- imitator solution and determination of electrochemical properties of the coatings were carried out. TFM of highly developed surface of contact with tissue was produced by argon plasma spraying of titanium powder with subsequent coating by titanium nitride in vacuum arc assisted by Ti ion implantation. The TFM coatings of pacemaker electrode have passed necessary clinical tests and were used in medical practice. They provide low voltage myocardium stimulation thresholds within the required operating time.

An investigation of flow-limited field-injection electrostatic spraying (FFESS) and its applications to thin film deposition

NASA Astrophysics Data System (ADS)

Singh, Ravindra Pratap

Electrostatic spraying is the process of controlled disruption of a liquid surface due to excess surface charge density. The technique has found applications in a wide range of fields from agricultural sprays to fuel injectors to colloidal thrusters for space vehicle propulsion. Over the past 20 years, the technique has been intensely studied in material processing for synthesis of ceramic and metal powders, nanoparticles and thin films. The importance of the technique lies in its simple setup, high deposition efficiency, and ambient atmosphere operation. In conventional electrostatic spraying (CESS), one uses a conducting nozzle to charge the liquid, mostly by induction charging. CESS is therefore restricted to the single jet mode of spraying which occurs at low spray currents. It lacks stability and reproducibility in the high current, multiple jet regime, which can generate much finer sprays. In flow-limited field-injection electrostatic spraying (FFESS), one uses a field-injection electrode to stably and controllably inject higher currents into the liquid, a la Fowler-Nordheim, using an otherwise insulating nozzle. This way, it is possible to stably electrospray in the multiple jet mode. In addition to producing much finer sprays, the multi-jet mode atomizes liquids at higher rates, and spreads the spray over a wider region and more uniformly than single jet sprays, thus paving way for large-area uniform thin film deposition. A simple yet comprehensive theory is formulated to describe the multi jet formation. The theory, which is based on the energy minimization principle, takes into account, for the first time, the interactions between charged jets which leads to saturation in the number of jets at high spray currents. The possibility of using an array of nozzles to obtain uniform large-area high-throughput thin film deposition is also investigated. A large number of FFESS nozzles with alternating positive and negative polarities arranged in a periodic 2-dimensional array are found to produce uniform thin films over large areas. Deposition of TiO2 and silver thin films using multi jet FFESS is studied, demonstrating great control on film morphology and properties. TiO2 thin films deposited on high-intensity discharge arc lamps are found to improve the quality of its light output. Silver thin films of high purity and conductivity, and with good adhesion, could be deposited at relatively high deposition rates and high deposition efficiency as compared to CVD techniques.

Implications of bio-efficacy and persistence of insecticides when indoor residual spraying and long-lasting insecticide nets are combined for malaria prevention

PubMed Central

2012-01-01

Background Bio-efficacy and residual activity of insecticides used for indoor residual spraying (IRS) and long-lasting insecticide nets (LLINs) were assessed against laboratory-reared and wild populations of the malaria vector, Anopheles arabiensis in south eastern Tanzania. Implications of the findings are examined in the context of potential synergies and redundancies where IRS and LLINs are combined. Methods Bioassays were conducted monthly for six months on three LLIN types (Olyset® PermaNet 2.0®,and Icon Life®) and three IRS treatments (2 g/m2 pirimiphos-methyl, 2 g/m2 DDT and 0.03 g/m2 lambda-cyhalothrin, sprayed on mud walls and palm ceilings of experimental huts). Tests used susceptible laboratory-reared An. arabiensis exposed in cones (nets and IRS) or wire balls (nets only). Susceptibility of wild populations was assessed using WHO diagnostic concentrations and PCR for knock-down resistance (kdr) genes. Results IRS treatments killed ≥ 85% of mosquitoes exposed on palm ceilings and ≥ 90% of those exposed on mud walls, but up to 50% of this toxicity decayed within 1–3 months, except for DDT. By 6th month, only 7.5%, 42.5% and 30.0% of mosquitoes died when exposed to ceilings sprayed with pirimiphos-methyl, DDT or lambda-cyhalothrin respectively, while 12.5%, 36.0% and 27.5% died after exposure to mud walls sprayed with the same insecticides. In wire-ball assays, mortality decreased from 98.1% in 1st month to 92.6% in 6th month in tests on PermaNet 2.0®, from 100% to 61.1% on Icon Life® and from 93.2% to 33.3% on Olyset® nets. In cone bioassays, mortality reduced from 92.8% in 1st month to 83.3% in 6th month on PermaNet 2.0®, from 96.9% to 43.80% on Icon Life® and from 85.6% to 14.6% on Olyset®. Wild An. arabiensis were 100% susceptible to DDT, 95.8% to deltamethrin, 90.2% to lambda cyhalothrin and 95.2% susceptible to permethrin. No kdr gene mutations were detected. Conclusions In bioassays where sufficient contact with treated surfaces is assured, LLINs and IRS kill high proportions of susceptible An. arabiensis mosquitoes, though these efficacies decay gradually for LLINs and rapidly for IRS. It is, therefore, important to always add intact nets in sprayed houses, guaranteeing protection even after the IRS decays, and to ensure accurate timing, quality control and regular re-spraying in IRS programmes. By contrast, adding IRS in houses with intact LLINs is unlikely to improve protection relative to LLINs alone, since there is no guarantee that unfed vectors would rest long enough on the sprayed surfaces, and because of the rapid IRS decay. However, there is need to clarify these effects using data from observations of free flying mosquitoes in huts. Physiological susceptibility of An. arabiensis in the area remains 100% against DDT, but is slightly reduced against pyrethroids, necessitating caution over possible spread of resistance. The loss of LLIN toxicity, particularly Olyset® nets suggests that protection offered by these nets against An. arabiensis may be primarily due to physical bite prevention rather than insecticidal efficacy. PMID:23164062

Implications of bio-efficacy and persistence of insecticides when indoor residual spraying and long-lasting insecticide nets are combined for malaria prevention.

PubMed

Okumu, Fredros O; Chipwaza, Beatrice; Madumla, Edith P; Mbeyela, Edgar; Lingamba, Geoffrey; Moore, Jason; Ntamatungro, Alex J; Kavishe, Deo R; Moore, Sarah J

2012-11-19

Bio-efficacy and residual activity of insecticides used for indoor residual spraying (IRS) and long-lasting insecticide nets (LLINs) were assessed against laboratory-reared and wild populations of the malaria vector, Anopheles arabiensis in south eastern Tanzania. Implications of the findings are examined in the context of potential synergies and redundancies where IRS and LLINs are combined. Bioassays were conducted monthly for six months on three LLIN types (Olyset® PermaNet 2.0®,and Icon Life®) and three IRS treatments (2 g/m2 pirimiphos-methyl, 2 g/m2 DDT and 0.03 g/m2 lambda-cyhalothrin, sprayed on mud walls and palm ceilings of experimental huts). Tests used susceptible laboratory-reared An. arabiensis exposed in cones (nets and IRS) or wire balls (nets only). Susceptibility of wild populations was assessed using WHO diagnostic concentrations and PCR for knock-down resistance (kdr) genes. IRS treatments killed ≥ 85% of mosquitoes exposed on palm ceilings and ≥ 90% of those exposed on mud walls, but up to 50% of this toxicity decayed within 1-3 months, except for DDT. By 6th month, only 7.5%, 42.5% and 30.0% of mosquitoes died when exposed to ceilings sprayed with pirimiphos-methyl, DDT or lambda-cyhalothrin respectively, while 12.5%, 36.0% and 27.5% died after exposure to mud walls sprayed with the same insecticides. In wire-ball assays, mortality decreased from 98.1% in 1st month to 92.6% in 6th month in tests on PermaNet 2.0®, from 100% to 61.1% on Icon Life® and from 93.2% to 33.3% on Olyset® nets. In cone bioassays, mortality reduced from 92.8% in 1st month to 83.3% in 6th month on PermaNet 2.0®, from 96.9% to 43.80% on Icon Life® and from 85.6% to 14.6% on Olyset®. Wild An. arabiensis were 100% susceptible to DDT, 95.8% to deltamethrin, 90.2% to lambda cyhalothrin and 95.2% susceptible to permethrin. No kdr gene mutations were detected. In bioassays where sufficient contact with treated surfaces is assured, LLINs and IRS kill high proportions of susceptible An. arabiensis mosquitoes, though these efficacies decay gradually for LLINs and rapidly for IRS. It is, therefore, important to always add intact nets in sprayed houses, guaranteeing protection even after the IRS decays, and to ensure accurate timing, quality control and regular re-spraying in IRS programmes. By contrast, adding IRS in houses with intact LLINs is unlikely to improve protection relative to LLINs alone, since there is no guarantee that unfed vectors would rest long enough on the sprayed surfaces, and because of the rapid IRS decay. However, there is need to clarify these effects using data from observations of free flying mosquitoes in huts. Physiological susceptibility of An. arabiensis in the area remains 100% against DDT, but is slightly reduced against pyrethroids, necessitating caution over possible spread of resistance. The loss of LLIN toxicity, particularly Olyset® nets suggests that protection offered by these nets against An. arabiensis may be primarily due to physical bite prevention rather than insecticidal efficacy.

Microstructure and corrosive wear resistance of plasma sprayed Ni-based coatings after TIG remelting

NASA Astrophysics Data System (ADS)

Tianshun, Dong; Xiukai, Zhou; Guolu, Li; Li, Liu; Ran, Wang

2018-02-01

Ni based coatings were prepared on steel substrate by means of plasma spraying, and were remelted by TIG (tungsten inert gas arc) method subsequently. The microstructure, microhardness, electrochemical corrosion and corrosive wear resistance under PH = 4, PH = 7 and PH = 10 conditions of the coatings before and after remelting were investigated. The results showed that the TIG remelting obviously reduced the defects and dramatically decreased the coating’s porosity from 7.2% to 0.4%. Metallurgical bonding between the remelted coating and substrate was achieved. Meanwhile, the phase compositions of as-sprayed coating were γ-Ni, Mn5Si2 and Cr2B, while the phase compositions of the remelting coating were Fe3Ni, Cr23C6, Cr2B and Mn5Si2. The microhardness of the coating decreased from 724 HV to 608 HV, but the fracture toughness enhanced from 2.80 MPa m1/2 to 197.3 MPa m1/2 after remelting. After corrosive wear test, the average wear weight loss and 3D morphology of wear scar of two coatings indicated that the wear resistance of the remelted coating was remarkably higher than that of as-sprayed coating. Therefore, TIG remelting treatment was a feasible method to improve the coating’s microstructure and enhance its corrosive wear resistance.

Effect of grit-blasting on substrate roughness and coating adhesion

NASA Astrophysics Data System (ADS)

Varacalle, Dominic J.; Guillen, Donna Post; Deason, Douglas M.; Rhodaberger, William; Sampson, Elliott

2006-09-01

Statistically designed experiments were performed to compare the surface roughness produced by grit blasting A36/1020 steel using different abrasives. Grit blast media, blast pressure, and working distance were varied using a Box-type statistical design of experiment (SDE) approach. The surface textures produced by four metal grits (HG16, HG18, HG25, and HG40) and three conventional grits (copper slag, coal slag, and chilled iron) were compared. Substrate roughness was measured using surface profilometry and correlated with operating parameters. The HG16 grit produced the highest surface roughness of all the grits tested. Aluminum and zinc-aluminum coatings were deposited on the grit-blasted substrates using the twin-wire electric are (TWEA) process. Bond strength of the coatings was measured with a portable adhesion tester in accordance with ASTM standard D 4541. The coatings on substrates roughened with steel grit exhibit superior bond strength to those prepared with conventional grit. For aluminum coatings sprayed onto surfaces prepared with the HG16 grit, the bond strength was most influenced by current, spray distance, and spray gun pressure (in that order). The highest bond strength for the zinc-aluminum coatings was attained on surfaces prepared using the metal grits.

A Controlled Arc Welding and Separation Processes for Carbon Nanotubes

NASA Technical Reports Server (NTRS)

Benavides, Jeannette; Shaw, Harry; Day, John H. (Technical Monitor)

2001-01-01

Stage 1 for the Carbon Nanotube Project has been completed. This videograph presents the proposal for Stage 2. The goals of this stage are to: (1) produce CNTs under different conditions such as cooling temperature, voltage, current, cathode and anode sizes; (2) use ferrocene to make longer CNTs; (3) characterize CNTs by spectroscopic methods; (4) develop applications of CNTs, i.e., batteries, composites, wires, etc.; and (5) complete the patent application.

The structure and physical-mechanical properties of the heat-resistant Ni-Co-Cr-Al-Y intermetallic coating obtained using rebuilt plasma equipment

NASA Astrophysics Data System (ADS)

Tarasenko, Yu. P.; Tsareva, I. N.; Berdnik, O. B.; Fel, Ya. A.; Kuzmin, V. I.; Mikhalchenko, A. A.; Kartaev, E. V.

2014-12-01

Results of a study of the structure, physico-mechanical properties, and the resistance to heat of Ni-Co-Cr-Al-Y intermetallic coatings obtained by powder spraying on the standard UPU-3D plasma spray facility (plasmatron with self-establishing arc length) and on the rebuilt facility equipped with the enhanced-power PNK-50 plasmatron with sectionalized inter-electrode insert, are reported. Coatings of higher density ( ρ = 7.9 g/cm3) and higher microhardness (H μ = 770 kg-force/mm2) with lower porosity values ( P = 5.7 %, P c = 5.1 %, and P 0 = 0.6 %) and high resistance to heat ((M - M0)/M0 = 1.2) were obtained. The developed coating is intended for protection of the working surfaces of turbine engine blades in gas-turbine power plants.

Diagnostics of thermal spraying plasma jets

NASA Astrophysics Data System (ADS)

Fauchais, P.; Coudert, J. F.; Vardelle, M.; Vardelle, A.; Denoirjean, A.

1992-06-01

The development of diagnostic techniques for dc plasma spraying is reviewed with attention given to the need for thick highly reproducible coatings of good quality for aeronautic and other uses. Among the techniques examined are fast cameras, laser-Doppler anemometry (LDA), coherent anti-Stokes Raman spectroscopy (CARS), enthalpy probes, and emission spectroscopy. Particular emphasis is given to the effect of arc fluctuations on the spectroscopic measurements, and a method is introduced for obtaining temperature and species density of vapor clouds traveling with each particle in flight. Coating properties can be deduced from data on single particles, and statistical approaches are often unreliable without added data on surface temperature and particle velocity. Also presented is a method for deriving the temperature evolution of a cooled splat and successive layers and passes. These methods are of interest to the control of adhesion and cohesion in coatings for critical aerospace applications.

Airborne exposure to inhalable hexavalent chromium in welders and other occupations: Estimates from the German MEGA database.

PubMed

Pesch, Beate; Kendzia, Benjamin; Hauptmann, Kristin; Van Gelder, Rainer; Stamm, Roger; Hahn, Jens-Uwe; Zschiesche, Wolfgang; Behrens, Thomas; Weiss, Tobias; Siemiatycki, Jack; Lavoué, Jerome; Jöckel, Karl-Heinz; Brüning, Thomas

2015-07-01

This study aimed to estimate occupational exposure to inhalable hexavalent chromium (Cr(VI)) using the exposure database MEGA. The database has been compiling Cr(VI) concentrations and ancillary data about measurements at German workplaces. We analysed 3659 personal measurements of inhalable Cr(VI) collected between 1994 and 2009. Cr(VI) was determined spectrophotometrically at 540 nm after reaction with diphenylcarbazide. We assigned the measurements to pre-defined at-risk occupations using the information provided about the workplaces. Two-thirds of the measurements were below the limit of quantification (LOQ) and multiply imputed according to the distribution above LOQ. The 75th percentile value was 5.2 μg/m(3) and the 95th percentile was 57.2 μg/m(3). We predicted the geometric mean for 2h sampling in the year 2000, and the time trend of Cr(VI) exposure in these settings with and without adjustment for the duration of measurements. The largest dataset was available for welding (N = 1898), which could be further detailed according to technique. The geometric means were above 5 μg/m(3) in the following situations: spray painting, shielded metal arc welding, and flux-cored arc welding if applied to stainless steel. The geometric means were between 1 μg/m(3) and 5 μg/m(3) for gas metal arc welding of stainless steel, cutting, hard-chromium plating, metal spraying and in the chemical chromium industry. The exposure profiles described here are useful for epidemiologic and industrial health purposes. Exposure to Cr(VI) varies not only between occupations, but also within occupations as shown for welders. In epidemiologic studies, it would be desirable to collect exposure-specific information in addition to the job title. Copyright © 2015 Elsevier GmbH. All rights reserved.

Mechanical behavior of NiTi arc wires under pseudoelastic cycling and cathodically hydrogen charging

NASA Astrophysics Data System (ADS)

Sarraj, R.; Hassine, T.; Gamaoun, F.

2018-01-01

NiTi wires are mainly used to design orthodontic devices. However, they may be susceptible to a delayed fracture while they are submitted to cyclic loading with the presence of hydrogen in the oral cavity. Hydrogen may cause the embrittlement of the structure, leading to lower ductility and to a change in transformation behavior. The aim of the present study is to predict the NiTi behavior under cyclic loading with hydrogen charging. One the one hand, samples are submitted to superelastic cyclic loading, which results in investigating their performance degradations. On the other hand, after hydrogen charging, cyclic tensile aging tests are carried out on NiTi orthodontic wires at room temperature in the air. During cyclic loading, we notice that the critical stress for the martensite transformation evolves, the residual strain is accumulated in the structure and the hysteresis loop changes. Thus, via this work, we can assume that the embrittlement is due to the diffusion of hydrogen and the generation of dislocations after aging. The evolution of mechanical properties of specimens becomes more significant with hydrogen charging rather than without it.

An effective and novel pore sealing agent to enhance the corrosion resistance performance of Al coating in artificial ocean water

NASA Astrophysics Data System (ADS)

Lee, Han-Seung; Singh, Jitendra Kumar; Ismail, Mohamed A.

2017-02-01

A new technique was accepted to fill the porosity of Al coating applied by arc thermal spray process to enhance corrosion resistance performance in artificial ocean water. The porosity is the inherent property of arc thermal spray coating process. In this study, applied coating was treated with different concentrations of ammonium phosphate mono basic (NH4H2PO4: AP) solution thereafter dried at room temperature and kept in humidity chamber for 7d to deposit uniform film. The corrosion resistance of Al coating and treated samples have been evaluated using electrochemical impedance spectroscopy (EIS) and potentiodynamic techniques with exposure periods in artificial ocean water. Electrochemical techniques, X-ray diffraction (XRD), Raman spectroscopy, atomic force microscopy (AFM) and field emission-scanning electron microscopy (FE-SEM) indicated that phosphate ion would have been retarding corrosion of Al coating effectively. The formation of AHP (Ammonium Aluminum Hydrogen Phosphate Hydrate: NH4)3Al5H6(PO4)8.18H2O) on Al coating surface after treatment with AP is nano sized, crystalline and uniformly deposited but after exposure them in artificial ocean water, they form AHPH (Aluminum hydroxide phosphate hydrate Al3(PO4)2(OH)3(H2O)5) that is very protective, adherent, uniform and plate like morphology of corrosion products. The AHPH is sparingly soluble and adherent to surface and imparted improved corrosion resistance.

Detection of metal-transfer mode in GMAW

DOE Office of Scientific and Technical Information (OSTI.GOV)

Johnson, J.A.; Carlson, N.M.; Smartt, H.B.

1989-01-01

One of the requirements of a sensing system for feedback control of gas metal arc welding (GMAW) is the capability to detect information about the metal-transfer mode. Because the operating boundary for the desired transfer mode, expressed as a function of mass input and heat input, may vary due to conditions beyond the control of the system, a means of determining the transfer mode during welding is necessary. A series of sensing experiments is performed during which the ultrasonic emissions, audio emissions, welding current fluctuations, and welding voltage fluctuations are recorded as a function of the transfer mode. In addition,more » high speed movies (5000 frame/s) of the droplet formation and detachment are taken synchronously with the sensing data. An LED mounted in the camera is used to work the film at the beginning and end of the data acquisition period. A second LED is pulsed at a 1 kHz rate and the pulses are recorded on film and with the sensor data. Thus events observed on the film can be correlated with the sensor data. Data acquired during globular transfer, spray transfer, and stiff spray or streaming transfer are observed to correlate with droplet detachment and arc shorting. The audio, current, and voltage data can be used to discriminate among these different transfer modes. However, the current and voltage data are also dependent on the characteristics of the welding power supply. 4 refs., 5 figs.« less

An effective and novel pore sealing agent to enhance the corrosion resistance performance of Al coating in artificial ocean water

PubMed Central

Lee, Han-Seung; Singh, Jitendra Kumar; Ismail, Mohamed A.

2017-01-01

A new technique was accepted to fill the porosity of Al coating applied by arc thermal spray process to enhance corrosion resistance performance in artificial ocean water. The porosity is the inherent property of arc thermal spray coating process. In this study, applied coating was treated with different concentrations of ammonium phosphate mono basic (NH4H2PO4: AP) solution thereafter dried at room temperature and kept in humidity chamber for 7d to deposit uniform film. The corrosion resistance of Al coating and treated samples have been evaluated using electrochemical impedance spectroscopy (EIS) and potentiodynamic techniques with exposure periods in artificial ocean water. Electrochemical techniques, X-ray diffraction (XRD), Raman spectroscopy, atomic force microscopy (AFM) and field emission-scanning electron microscopy (FE-SEM) indicated that phosphate ion would have been retarding corrosion of Al coating effectively. The formation of AHP (Ammonium Aluminum Hydrogen Phosphate Hydrate: NH4)3Al5H6(PO4)8.18H2O) on Al coating surface after treatment with AP is nano sized, crystalline and uniformly deposited but after exposure them in artificial ocean water, they form AHPH (Aluminum hydroxide phosphate hydrate Al3(PO4)2(OH)3(H2O)5) that is very protective, adherent, uniform and plate like morphology of corrosion products. The AHPH is sparingly soluble and adherent to surface and imparted improved corrosion resistance. PMID:28157233

Parametric studies on tensile strength in joining AA6061- T6 and AA7075-T6 by gas metal arc welding process

NASA Astrophysics Data System (ADS)

Ishak, M.; Noordin, N. F. M.; Shah, L. H.

2015-12-01

Proper selection of the welding parameters can result in better joining. In this study, the effects of various welding parameters on tensile strength in joining dissimilar aluminum alloys AA6061-T6 and AA7075-T6 were investigated. 2 mm thick samples of both base metals were welded by semi-automatic gas metal arc welding (GMAW) using filler wire ER5356. The welding current, arc voltage and welding speed were chosen as variables parameters. The strength of each specimen after the welding operations were tested and the effects of these parameters on tensile strength were identified by using Taguchi method. The range of parameter for welding current were chosen from 100 to 115 A, arc voltage from 17 to 20 V and welding speed from 2 to 5 mm/s. L16 orthogonal array was used to obtained 16 runs of experiments. It was found that the highest tensile strength (194.34 MPa) was obtained with the combination of a welding current of 115 A, welding voltage of 18 V and welding speed of 4 mm/s. Through analysis of variance (ANOVA), the welding voltage was the most effected parameter on tensile strength with percentage of contribution at 41.30%.

Laser-based welding of 17-4 PH martensitic stainless steel in a tubular butt joint configuration with a built-in backing bar

NASA Astrophysics Data System (ADS)

Ma, Junjie; Atabaki, Mehdi Mazar; Liu, Wei; Pillai, Raju; Kumar, Biju; Vasudevan, Unnikrishnan; Kovacevic, Radovan

2016-08-01

Laser-based welding of thick 17-4 precipitation hardening (PH) martensitic stainless steel (SS) plates in a tubular butt joint configuration with a built-in backing bar is very challenging because the porosity and cracks are easily generated in the welds. The backing bar blocked the keyhole opening at the bottom surface through which the entrapped gas could escape, and the keyhole was unstable and collapsed overtime in a deep partially penetrated welding conditions resulting in the formation of pores easily. Moreover, the fast cooling rate prompted the ferrite transform to austenite which induced cracking. Two-pass welding procedure was developed to join 17-4 PH martensitic SS. The laser welding assisted by a filler wire, as the first pass, was used to weld the groove shoulder. The added filler wire could absorb a part of the laser beam energy; resulting in the decreased weld depth-to-width ratio and relieved intensive restraint at the weld root. A hybrid laser-arc welding or a gas metal arc welding (GMAW) was used to fill the groove as the second pass. Nitrogen was introduced to stabilize the keyhole and mitigate the porosity. Preheating was used to decrease the cooling rate and mitigate the cracking during laser-based welding of 17-4 PH martensitic SS plates.

Effects of anchoring and arc structure on the control authority of a rail plasma actuator

NASA Astrophysics Data System (ADS)

Choi, Young-Joon; Gray, Miles; Sirohi, Jayant; Raja, Laxminarayan L.

2017-09-01

Experiments were conducted on a rail plasma actuator (RailPAc) with different electrode cross sections (rails or rods) to assess methods to improve the actuation authority, defined as the impulse generated for a given electrical input. The arc was characterized with electrical measurements and high-speed images, while impulse measurements quantified the actuation authority. A RailPAc power supply capable of delivering  ∼1 kA of current at  ∼100 V was connected to rod electrodes (free-floating with circular cross-section) and rail electrodes (flush-mounted in a flat plate with rectangular cross-section). High-speed images show that the rail electrodes cause the arc to anchor itself to the anode electrode and transit in discrete jumps, while rod electrodes permit the arc to transit smoothly without anchoring. The impulse measurements reveal that the anchoring reduces the actuation authority by  ∼21% compared to a smooth transit, and the effect of anchoring can be suppressed by reducing the gap between the rails to 2 mm. The study further demonstrates that if a smooth transit is achieved, the control authority can be increased with a larger gap and larger arc current. In conclusion, the actuation authority of a RailPAc can be maximized by carefully choosing a gap width that prevents anchoring. Further study is warranted to increase the RailPAc actuation authority by introducing multiple turns of wires beneath the RailPAc to augment the induced magnetic field.

A New Model for Simulating Gas Metal Arc Welding based on Phase Field Model

NASA Astrophysics Data System (ADS)

Jiang, Yongyue; Li, Li; Zhao, Zhijiang

2017-11-01

Lots of physical process, such as metal melting, multiphase fluids flow, heat and mass transfer and thermocapillary effect (Marangoni) and so on, will occur in gas metal arc welding (GMAW) which should be considered as a mixture system. In this paper, based on the previous work, we propose a new model to simulate GMAW including Navier-Stokes equation, the phase field model and energy equation. Unlike most previous work, we take the thermocapillary effect into the phase field model considering mixture energy which is different of volume of fluid method (VOF) widely used in GMAW before. We also consider gravity, electromagnetic force, surface tension, buoyancy effect and arc pressure in momentum equation. The spray transfer especially the projected transfer in GMAW is computed as numerical examples with a continuous finite element method and a modified midpoint scheme. Pulse current is set as welding current as the numerical example to show the numerical simulation of metal transfer which fits the theory of GMAW well. From the result compared with the data of high-speed photography and VOF model, the accuracy and stability of the model and scheme are easily validated and also the new model has the higher precieion.

Impact of different welding techniques on biological effect markers in exhaled breath condensate of 58 mild steel welders.

PubMed

Hoffmeyer, Frank; Raulf-Heimsoth, Monika; Lehnert, Martin; Kendzia, Benjamin; Bernard, Sabine; Berresheim, Hans; Düser, Maria; Henry, Jana; Weiss, Tobias; Koch, Holger M; Pesch, Beate; Brüning, Thomas

2012-01-01

Total mass and composition of welding fumes are predominantly dependent on the welding technique and welding wire applied. The objective of this study was to investigate the impact of welding techniques on biological effect markers in exhaled breath condensate (EBC) of 58 healthy welders. The welding techniques applied were gas metal arc welding with solid wire (GMAW) (n=29) or flux cored wire (FCAW) (n=29). Welding fume particles were collected with personal samplers in the breathing zone inside the helmets. Levels of leukotriene B(4) (LTB(4)), prostaglandin E(2) (PGE(2)), and 8-isoprostane (8-iso-PGF(2α)) were measured with immunoassay kits and the EBC pH was measured after deaeration. Significantly higher 8-iso-PGF(2α) concentrations and a less acid pH were detected in EBC of welders using the FCAW than in EBC of welders using the GMAW technique. The lowest LTB(4) concentrations were measured in nonsmoking welders applying a solid wire. No significant influences were found in EBC concentrations of PGE(2) based upon smoking status or type of welding technique. This study suggests an enhanced irritative effect in the lower airways of mild steel welders due to the application of FCAW compared to GMAW, most likely associated with a higher emission of welding fumes.

Stress Corrosion Cracking Susceptibility of 304L Substrate and 308L Weld Metal Exposed to a Salt Spray

PubMed Central

Hsu, Chia-Hao; Chen, Tai-Cheng; Huang, Rong-Tan; Tsay, Leu-Wen

2017-01-01

304 stainless steels (SS) were considered as the materials for a dry storage canister. In this study, ER (Electrode Rod) 308L was utilized as the filler metal for the groove and overlay welds of a 304L stainless steel substrate, which was prepared via a gas tungsten arc-welding process in multiple passes. The electron backscatter diffraction (EBSD) map was used to identify the inherent microstructures in distinct specimens. U-bend and weight-loss tests were conducted by testing the 304L substrates and welds in a salt spray containing 5 wt % NaCl at 80 °C to evaluate their susceptibility to stress corrosion cracking (SCC). Generally, the weight loss of the ER 308L deposit was higher than that of the 304L substrate in a salt spray in the same sample-prepared condition. The dissolution of the skeletal structure in the fusion zone (FZ) was responsible for a greater weight loss of the 308L deposit, especially for the cold-rolled and sensitized specimen. Cold rolling was detrimental and sensitization after cold rolling was very harmful to the SCC resistance of the 304L substrate and 308L deposit. Overall, the SCC susceptibility of each specimen was correlated with its weight loss in each group. PMID:28772547

Development of a Self-Sluicing Pressure Leaf Filter

NASA Astrophysics Data System (ADS)

Cousineau, Bernard L.; Lumsden, J. R.

The cylindrical Kelly filter presses installed in the Ewarton Works "C" phase did not perform satisfactorily because of difficulties with head seals, locking rings, and shell retraction mechanisms. As rectification required major modifications, a concept of a press which did not require to be opened for sluicing was proposed. Test work of various sluicing and res lurrying spray arrangements was carried out, and this led to the design of a self-sluicing press which used the shell of an existing Kelly press with its main axis vertical. One press was converted by July 1972, and a development period started. Although initial operation was encouraging, effective sluicing could not be guaranteed after 30 shifts. Modifications to leaf spacing, spray rotational speed, spray slot width, feed pressure and pre-coat control by November 1973, however, allowed effective performance for all of the 800 hour canvas life. Advantages are: reduced operating and maintenance manpower, clean environment, and reduced maintenance cost. The use of 1st wash overflow for sluicing has reduced caustic soda and canvas consumption. Ewarton Works now has four converted self-sluicing presses, and arc converting five more, and Arvida Works plan the installation of one for tests on red pressing (blow-off filtration). A side benefit of the development was the study of the benefits of constant pressure overflow filtration.

RF Coupling into the Fuel Tank of a Large Transport Aircraft from Intentionally Transmitting Peds in the Passenger Cabin

NASA Technical Reports Server (NTRS)

Nguyen, Truong X.; Dudley, Kenneth L.; Scearce, Stephen A.; Ely, Jay J.; Richardson, Robert E.; Hatfield, Michael O.

2000-01-01

An investigation was performed to study the potential for radio frequency (RF) power radiated from Portable Electronic Devices (PEDs) to create an arcing/sparking event within the fuel tank of a large transport aircraft. This paper describes the experimental methods used for measuring RF coupling to the fuel tank and Fuel Quantity Indication System (FQIS) wiring from PED sources located in the passenger cabin. To allow comparison of voltage/current data obtained in a laboratory chamber FQIS installation to an actual aircraft FQIS installation, aircraft fuel tank RF reverberation characteristics were also measured. Results from the measurements, along with a survey of threats from typical intentional transmitting PEDs are presented. The resulting worst-case power coupled onto fuel tank FQIS wiring is derived. The same approach can be applied to measure RF coupling into various other aircraft systems.

Ideal tibial intramedullary nail insertion point varies with tibial rotation.

PubMed

Walker, Richard M; Zdero, Rad; McKee, Michael D; Waddell, James P; Schemitsch, Emil H

2011-12-01

The aim of the study was to investigate how superior entry point varies with tibial rotation and to identify landmarks that can be used to identify suitable radiographs for successful intramedullary nail insertion. The proximal tibia and knee were imaged for 12 cadaveric limbs undergoing 5° increments of internal and external rotation. Medial and lateral arthrotomies were performed, the ideal superior entry point was identified, and a 2-mm Kirschner wire inserted. A second Kirschner wire was sequentially placed at the 5-mm and then the 10-mm position, both medial and lateral to the initial Kirschner wire. Radiographs of the knee were obtained for all increments. The changing position of the ideal nail insertion point was recorded. A 30° arc (range, 25°-40°) provided a suitable anteroposterior radiograph. On the neutral anteroposterior radiograph, the Kirschner wire was 54% ± 1.5% (range, 51-56%) from the medial edge of the tibial plateau. For every 5° of rotation, the Kirschner wire moved 3% of the plateau width. During external rotation, a misleading medial entry point was obtained. A fibular bisector line correlated with an entry point that was ideal or up to 5 mm lateral to this but never medial. The film that best showed the fibular bisector line was between 0° and 10° of internal rotation of the tibia. The fibula head bisector line can be used to avoid choosing external rotation views and, thus, avoid medial insertion points. The current results may help the surgeon prevent malalignment during intramedullary nailing in proximal tibial fractures.

The use of cold sprayed alloys for metallic stents

NASA Astrophysics Data System (ADS)

AL-Mangour, Bandar

With the invention of the coronary stent, which is a wire metal mesh tube designed to keep the arteries open in the treatment of heart diseases, promising clinical outcomes were generated. However, the long term successes of stents have been delayed by significant in-stent restenosis (blockages) and stent fracture. In this research work, it has been proposed to use Cold Gas Dynamic Spraying (CGDS) coating material as an alternative choice to manufacture metallic stent. In CGDS, fine particles are accelerated to a high velocity and undergo solid-state plastic deformation upon impact on the substrate, which leads to particle-particle bonding. The feature of CGDS distinct from other thermal spray techniques is that the processing gas temperature is below the melting point of the feedstock. Therefore, unwanted effects of high temperatures, such as oxidation, grain growth and thermal stresses, are absent. In response to the fact that the majority of stents are made from stainless steel (316L) or Co-Cr alloy (L605), this study specifically addresses the development and characterization of 316L and 316L mixed with L605 coatings produced by the CGDS process. Scanning electron microscopy and electron backscatter diffraction were used to investigate the microstructural changes of these coatings before and after annealing. The effect of gas type on the microstructure of 316L coatings and the role of post-heat treatment in the microstructure and properties are also studied. Of particular interest are grain refinement, heat treatment, mechanical properties and corrosion behavior of the cold sprayed material.

Multiple exposure to metals in eight types of welding.

PubMed

Apostoli, P; Porru, S; Brunelli, E; Alessio, L

1997-01-01

This article evaluates multiple exposures to metals in different types of metal welding such as manual metal arc for mild and stainless steel, continuous wire, submerged arc, laser and brazing. Environmental monitoring was carried out in eight different occupational situations and the inductively coupled plasma mass spectrometry technique was adopted in order to characterize exposure to several elements simultaneously and with high accuracy. The results showed that up to 23 elements could be measured. The highest concentrations were found for Al, Mn, Fr, Ni, Cr, Cu and Zn. For some elements such as In, Nd, I, Rb the concentrations were very low. A qualitative and quantitative variation in fume composition was observed at a certain distance from the welding point, which should be to taken into account when evaluating indirect exposures. It would also be possible, with this technique, to identify specific elements in the mixture which could also be measured in biological fluids.

Models for selecting GMA Welding Parameters for Improving Mechanical Properties of Weld Joints

NASA Astrophysics Data System (ADS)

Srinivasa Rao, P.; Ramachandran, Pragash; Jebaraj, S.

2016-02-01

During the process of Gas Metal Arc (GMAW) welding, the weld joints mechanical properties are influenced by the welding parameters such as welding current and arc voltage. These parameters directly will influence the quality of the weld in terms of mechanical properties. Even small variation in any of the cited parameters may have an important effect on depth of penetration and on joint strength. In this study, S45C Constructional Steel is taken as the base metal to be tested using the parameters wire feed rate, voltage and type of shielding gas. Physical properties considered in the present study are tensile strength and hardness. The testing of weld specimen is carried out as per ASTM Standards. Mathematical models to predict the tensile strength and depth of penetration of weld joint have been developed by regression analysis using the experimental results.

Welding needs specified for X-80 offshore line pipe

DOE Office of Scientific and Technical Information (OSTI.GOV)

Price, J.C.

1993-12-20

High-quality, defect-free welds can be deposited in API Grade 5L X-80 line pipe with pulsed gas-metal-arc welding (GMAW) and shielded metal-arc welding (SMAW) processes. The newly developed Grade X-80 combines higher yield-strength pipe with thinner walls to reduce fabrication costs and improve some projects' economics. Use of X-80 pipe can yield as much as 7.5% cost savings over construction with X-65 steel. Increased demand of natural gas has prompted development of large gas fields which will require large-diameter pipelines at higher operating pressures. API 5L X-80 line pipe could, therefore, become commonplace by the end of the decade if weldingmore » technology can be developed to match mechanical properties without affecting productivity. The paper discusses large-diameter projects, welding processes, GMAW shielding gas, SMAW filler wires, hardness and weldability, toughness and corrosion resistance, economics, and what's been learned.« less

Nuclear valve manufacturer selects stainless forgings

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

1976-02-01

Forged type 316 stainless steel components for nuclear valves are described. Automatic plasma arc welding with powder filler alloys is employed for hardfacing. Seat ring forgings are surfaced four-at-a-time with Stellite No. 156 in a sequential manner to minimize heat input to the individual components. After cladding and machining, seat rings are welded into the valve body using a semiautomatic, hot-wire gas tungsten-arc process. Disc faces and guide slots are surfaced with Stellite No. 6. The valve stem is machined from 17-4PH forged bar stock in the H-1100 condition. The heat treatment is specified to minimize pitting under prolonged exposuremore » to wet packing. A 12 rms (0.3 $mu$m) surface finish minimizes tearing of the packing and subsequent leakage. The link and stem pin are SA 564 Grade 660 (in the H-1100 condition) and ASTM A637 Grade 718 respectively. (JRD)« less

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

NASA Technical Reports Server (NTRS)

Fernandez, Ken; Cook, George E.

1988-01-01

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.

The role of rapid solidification processing in the fabrication of fiber reinforced metal matrix composites

NASA Technical Reports Server (NTRS)

Locci, Ivan E.; Noebe, Ronald D.

1989-01-01

Advanced composite processing techniques for fiber reinforced metal matrix composites require the flexibility to meet several widespread objectives. The development of uniquely desired matrix microstructures and uniformly arrayed fiber spacing with sufficient bonding between fiber and matrix to transmit load between them without degradation to the fiber or matrix are the minimum requirements necessary of any fabrication process. For most applications these criteria can be met by fabricating composite monotapes which are then consolidated into composite panels or more complicated components such as fiber reinforced turbine blades. Regardless of the end component, composite monotapes are the building blocks from which near net shape composite structures can be formed. The most common methods for forming composite monotapes are the powder cloth, foil/fiber, plasma spray, and arc spray processes. These practices, however, employ rapid solidification techniques in processing of the composite matrix phase. Consequently, rapid solidification processes play a vital and yet generally overlooked role in composite fabrication. The future potential of rapid solidification processing is discussed.

Hot Forging of a Cladded Component by Automated GMAW Process

NASA Astrophysics Data System (ADS)

Rafiq, Muhammad; Langlois, Laurent; Bigot, Régis

2011-01-01

Weld cladding is employed to improve the service life of engineering components by increasing corrosion and wear resistance and reducing the cost. The acceptable multi-bead cladding layer depends on single bead geometry. Hence, in first step, the relationship between input process parameters and the single bead geometry is studied and in second step a comprehensive study on multi bead clad layer deposition is carried out. This paper highlights an experimental study carried out to get single layer cladding deposited by automated Gas Metal Arc Welding (GMAW) process and to find the possibility of hot forming of the cladded work piece to get the final hot formed improved structure. GMAW is an arc welding process that uses an arc between a consumable electrode and the welding pool with an external shielding gas and the cladding is done by alongside deposition of weld beads. The experiments for single bead were conducted by varying the three main process parameters wire feed rate, arc voltage and welding speed while keeping other parameters like nozzle to work distance, shielding gas and its flow rate and torch angle constant. The effect of bead spacing and torch orientation on the cladding quality of single layer from the results of single bead deposition was studied. Effect of the dilution rate and nominal energy on the cladded layer hot bending quality was also performed at different temperatures.

Gas metal arc welding fume generation using pulsed current

DOE Office of Scientific and Technical Information (OSTI.GOV)

Castner, H.R.

1994-12-31

This paper describes a study of the effects of pulsed welding current on the amount of welding fume and ozone produced during gas metal arc welding (GMAW) using a range of welding procedures and pulse parameters. The results reported in this paper show that pulsed current can reduce GMAW fumes compared to steady current. This research also shows that welding parameters need to be properly controlled if pulsed current is to be used to reduce welding fumes. Fume and ozone generation rates were measured during this study for GMAW of mild steel using copper-coated ER70S-3 electrode wire and 95%Ar-5%CO{sub 2}more » and 85%Ar-15%CO{sub 2} shielding gases. Welds were made with both steady current and pulsed current over a wide range of welding parameters. Fume generation rates for steady current were found to be typically between 0.2 g/min and 0.8 g/min which agrees with other researchers. No significant difference was found in the chemical composition of welding fumes from pulsed current compared to the composition of fumes generated by steady current. New technology that can reduce arc welding fumes is of significant interest to a wide range of companies that use arc welding processes and this research should assist these users in evaluating the potential for the application of this technology to their own operations.« less

Study of MA Effect on Yield Strength and Ductility of X80 Linepipe Steels Weld

NASA Astrophysics Data System (ADS)

Huda, Nazmul; Lazor, Robert; Gerlich, Adrian P.

2017-09-01

Multipass GMAW (Gas Metal Arc Welding) welding was used to join X80 linepipe materials using two weld metals of slightly different compositions. Welding wires with diameters of 0.984 and 0.909 mm were used while applying the same heat input in each pass. The slight difference in the wire diameters resulted in different HAZ microstructures. The microstructures in the doubly reheated HAZ of both welds were found to contain bainite-ferrite. However, etching also revealed a difference in martensite-austenite (MA) fraction in these reheated zones. The MA exhibited twice the hardness of ferrite when measured by nanoindentation. Tensile testing from the reheated zone of both welds revealed a difference in yield strength, tensile strength and elongation of the transverse weld specimens. In the reheated zone of weld A, (produced with a 0.984 mm wire) a higher fraction of MA was observed, which resulted in higher strength but lower elongation compared to weld B. The ductility of weld A was found severely impaired (to nearly half of weld B) due to formation of closely spaced voids around the MA, along with debonding of MA from the matrix, which occurs just above the yield stress.

Evaluation of Risk and Possible Mitigation Schemes for Previously Unidentified Hazards

NASA Technical Reports Server (NTRS)

Linzey, William; McCutchan, Micah; Traskos, Michael; Gilbrech, Richard; Cherney, Robert; Slenski, George; Thomas, Walter, III

2006-01-01

In April 2004, the NASA Engineering and Safety Center (NESC) was commissioned by NASA's Chief Safety and Mission Assurance (S&MA) Officer to review and render a technical opinion on the probability of a catastrophic failure related to this scenario: The Space Shuttle Program (SSP) recognized a zero-fault-tolerant design related to an inadvertent firing of the primary reaction control system (RCS) jets on the Orbiter during mated operations with the International Space Station (ISS). It was determined that an un-commanded firing of an RCS jet could cause serious damage or loss of both the SSP Orbiter and the ISS. Several scenarios were suggested in which an un-commanded firing of the RCS jet is possible. These scenarios include an arc track event in the 28-volt heater circuits that could result in a wire-to-wire short to the adjacent reaction control jet wire. In this worst-case scenario, enough current and power could be applied to activate the reaction control jet valves and fire a thruster. The following report summarizes the work that was sponsored by the NESC as part of their assessment of the Orbiter inadvertent firing of a RCS thruster while attached to the ISS.

Studies on microstructure, mechanical and pitting corrosion behaviour of similar and dissimilar stainless steel gas tungsten arc welds

NASA Astrophysics Data System (ADS)

Mohammed, Raffi; Dilkush; Srinivasa Rao, K.; Madhusudhan Reddy, G.

2018-03-01

In the present study, an attempt has been made to weld dissimilar alloys of 5mm thick plates i.e., austenitic stainless steel (316L) and duplex stainless steel (2205) and compared with that of similar welds. Welds are made with conventional gas tungsten arc welding (GTAW) process with two different filler wires namely i.e., 309L and 2209. Welds were characterized using optical microscopy to observe the microstructural changes and correlate with mechanical properties using hardness, tensile and impact testing. Potentio-dynamic polarization studies were carried out to observe the pitting corrosion behaviour in different regions of the welds. Results of the present study established that change in filler wire composition resulted in microstructural variation in all the welds with different morphology of ferrite and austenite. Welds made with 2209 filler showed plate like widmanstatten austenite (WA) nucleated at grain boundaries. Compared to similar stainless steel welds inferior mechanical properties was observed in dissimilar stainless steel welds. Pitting corrosion resistance is observed to be low for dissimilar stainless steel welds when compared to similar stainless steel welds. Overall study showed that similar duplex stainless steel welds having favorable microstructure and resulted in better mechanical properties and corrosion resistance. Relatively dissimilar stainless steel welds made with 309L filler obtained optimum combination of mechanical properties and pitting corrosion resistance when compared to 2209 filler and is recommended for industrial practice.

Process Modeling and Validation for Metal Big Area Additive Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Simunovic, Srdjan; Nycz, Andrzej; Noakes, Mark W.

Metal Big Area Additive Manufacturing (mBAAM) is a new additive manufacturing (AM) technology based on the metal arc welding. A continuously fed metal wire is melted by an electric arc that forms between the wire and the substrate, and deposited in the form of a bead of molten metal along the predetermined path. Objects are manufactured one layer at a time starting from the base plate. The final properties of the manufactured object are dependent on its geometry and the metal deposition path, in addition to depending on the basic welding process parameters. Computational modeling can be used to acceleratemore » the development of the mBAAM technology as well as a design and optimization tool for the actual manufacturing process. We have developed a finite element method simulation framework for mBAAM using the new features of software ABAQUS. The computational simulation of material deposition with heat transfer is performed first, followed by the structural analysis based on the temperature history for predicting the final deformation and stress state. In this formulation, we assume that two physics phenomena are coupled in only one direction, i.e. the temperatures are driving the deformation and internal stresses, but their feedback on the temperatures is negligible. The experiment instrumentation (measurement types, sensor types, sensor locations, sensor placements, measurement intervals) and the measurements are presented. The temperatures and distortions from the simulations show good correlation with experimental measurements. Ongoing modeling work is also briefly discussed.« less

Properties of thermal air plasma with admixing of copper and carbon

NASA Astrophysics Data System (ADS)

Fesenko, S.; Veklich, A.; Boretskij, V.; Cressault, Y.; Gleizes, A.; Teulet, Ph

2014-11-01

This paper deals with investigations of air plasma with admixing of copper and carbon. Model plasma source unit with real breaking arc was used for the simulation of real discharges, which can be occurred during sliding of Cu-C composite electrodes on copper wire at electromotive vehicles. The complex technique of plasma property studies is developed. From one hand, the radial profiles of temperature and electron density in plasma of electric arc discharge in air between Cu-C composite and copper electrodes in air flow were measured by optical spectroscopy techniques. From another hand, the radial profiles of electric conductivity of plasma mixture were calculated by solution of energy balance equation. It was assumed that the thermal conductivity of air plasma is not depending on copper or carbon vapor admixtures. The electron density is obtained from electric conductivity profiles by calculation in assumption of local thermodynamic equilibrium in plasma. Computed in such way radial profiles of electron density in plasma of electric arc discharge in air between copper electrodes were compared with experimentally measured profiles. It is concluded that developed techniques of plasma diagnostics can be reasonably used in investigations of thermal plasma with copper and carbon vapors.

Effect of Helmholtz Oscillation on Auto-shroud for APS Tungsten Carbide Coating

NASA Astrophysics Data System (ADS)

Jin, Younggil; Choi, Sooseok; Yang, Seung Jae; Park, Chong Rae; Kim, Gon-Ho

2013-06-01

The atmospheric-pressure plasma spray (APS) of tungsten coating was performed using tungsten carbide (WC) powder by means of DC plasma torch equipped with a stepped anode nozzle as a potential method of W coating on graphite plasma-facing component of fusion reactors. This nozzle configuration allows Helmholtz oscillation mode dominating in APS arc fluctuation, and the variation of auto-shroud effect with Helmholtz oscillation characteristics can be investigated. Tungsten coating made from WC powder has lower porosity and higher tungsten purity than that made from pure tungsten powder. The porosity and chemical composition of coatings were investigated by mercury intrusion porosimetry and x-ray photoelectron spectroscopy, respectively. The purity of tungsten coating layer is increased with the increasing frequency of Helmholtz oscillation and the increasing arc current. The modulation of Helmholtz oscillation frequency and magnitude may enhance the decarburization of WC to deposit tungsten coating without W-C and W-O bond from WC powder.

The effect of the welding direction on the plasma and metal transfer behavior of CO2 laser+GMAW-P hybrid welding processes

NASA Astrophysics Data System (ADS)

Zhang, Wang; Hua, Xueming; Liao, Wei; Li, Fang; Wang, Min

2014-07-01

During laser-arc hybrid welding, the welding direction exerts direct effects on the plasma properties, the transient behavior of the droplet, the weld pool behavior, and the temperature field. Ultimately, it will affect the welding process and the weld quality. However, the behavior of the CO2 laser+GMAW-P hybrid welding process has not been systematically studied. In this paper, the current-voltage characteristics of different welding processes were analyzed and compared. The dynamics of the droplet transfer, the plasma behavior, and the weld pool behavior were observed by using two high-speed camera systems. Moreover, an optical emission spectroscopy was applied to analyze the plasma temperature and the electron number density. The results indicated that the electrical resistance of the arc plasma reduced in the laser leading mode. For the same pulse duration, the metal transfer mode was the spray type with the laser leading arrangement. The temperature and electron density distribution showed bimodal behavior in the case of arc leading mode, while this phenomenon does not exist in the caser of laser leading mode. The double elliptic-planar distribution which conventional simulation process used was not applicable in the laser leading mode.

Hydrogen plasma tests of some insulating coating systems for the nuclear rocket thrust chamber

NASA Technical Reports Server (NTRS)

Current, A. N.; Grisaffe, S. J.; Wycoff, K. C.

1972-01-01

Several plasma-sprayed and slurry-coated insulating coating systems were evaluated for structural stability in a low-pressure hot hydrogen environment at a maximum heat flux of 19.6 million watts/sq meter. The heat was provided by an electric-arc plasma generator. The coating systems consisted of a number of thin layers of metal oxides and/or metals. The materials included molybdenum, nichrome, tungsten, alumina, zirconia, and chromia. The study indicates potential usefulness in this environment for some coatings, and points up the need for improved coating application techniques.

Laboratory performance of zinc anodes for impressed current cathodic protection of reinforced concrete

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brousseau, R.; Arnott, M.; Baldock, B.

1995-08-01

Cathodic protection is used increasingly to mitigate steel reinforcement corrosion in concrete. the performance of zinc materials as impressed current anodes was evaluated. The anode materials investigated included rolled zinc sheets, metallized zinc, and 85% Zn-15% Al. The circuit resistance and the adhesion of the anodes was monitored with polarization time. Overall performance of arc-sprayed zinc was good. However, its adhesion to the concrete surface slowly decreased as the current density, or the polarization period, increased. Penny blank sheets and metallized 85% Zn-15% Al were found unsuitable as impressed current anodes.

Electrical termination techniques

NASA Technical Reports Server (NTRS)

Oakey, W. E.; Schleicher, R. R.

1976-01-01

A technical review of high reliability electrical terminations for electronic equipment was made. Seven techniques were selected from this review for further investigation, experimental work, and preliminary testing. From the preliminary test results, four techniques were selected for final testing and evaluation. These four were: (1) induction soldering, (2) wire wrap, (3) percussive arc welding, and (4) resistance welding. Of these four, induction soldering was selected as the best technique in terms of minimizing operator errors, controlling temperature and time, minimizing joint contamination, and ultimately producing a reliable, uniform, and reusable electrical termination.

Error studies of Halbach Magnets

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brooks, S.

2017-03-02

These error studies were done on the Halbach magnets for the CBETA “First Girder” as described in note [CBETA001]. The CBETA magnets have since changed slightly to the lattice in [CBETA009]. However, this is not a large enough change to significantly affect the results here. The QF and BD arc FFAG magnets are considered. For each assumed set of error distributions and each ideal magnet, 100 random magnets with errors are generated. These are then run through an automated version of the iron wire multipole cancellation algorithm. The maximum wire diameter allowed is 0.063” as in the proof-of-principle magnets. Initially,more » 32 wires (2 per Halbach wedge) are tried, then if this does not achieve 1e-­4 level accuracy in the simulation, 48 and then 64 wires. By “1e-4 accuracy”, it is meant the FOM defined by √(Σ n≥sextupole a n 2+b n 2) is less than 1 unit, where the multipoles are taken at the maximum nominal beam radius, R=23mm for these magnets. The algorithm initially uses 20 convergence interations. If 64 wires does not achieve 1e-­4 accuracy, this is increased to 50 iterations to check for slow converging cases. There are also classifications for magnets that do not achieve 1e-4 but do achieve 1e-3 (FOM ≤ 10 units). This is technically within the spec discussed in the Jan 30, 2017 review; however, there will be errors in practical shimming not dealt with in the simulation, so it is preferable to do much better than the spec in the simulation.« less

Sixty-four-Channel Inline Cable Tester

NASA Technical Reports Server (NTRS)

2008-01-01

Faults in wiring are a serious concern for the aerospace and aeronautics (commercial, military, and civil) industries. A number of accidents have occurred because faulty wiring created shorts or opens that resulted in the loss of control of the aircraft or because arcing led to fires and explosions. Some of these accidents have resulted in the massive loss of lives (such as in the TWA Flight 800 accident). Circuits on the Space Shuttle have also failed because of faulty insulation on wiring. STS-93 lost power when a primary power circuit in one engine failed and a second engine had a backup power circuit fault. Cables are usually tested on the ground after the crew reports a fault encountered during flight. Often such failures result from vibration and cannot be replicated while the aircraft is stationary. It is therefore important to monitor faults while the aircraft is in operation, when cables are more likely to fail. Work is in progress to develop a cable fault tester capable of monitoring up to 64 individual wires simultaneously. Faults can be monitored either inline or offline. In the inline mode of operation, the monitoring is performed without disturbing the normal operation of the wires under test. That is, the operations are performed unintrusively and are essentially undetectable for the test signal levels are below the noise floor. A cable can be monitored several times per second in the offline mode and once a second in the inline mode. The 64-channel inline cable tester not only detects the occurrence of a fault, but also determines the type of fault (short/open) and the location of the fault. This will enable the detection of intermittent faults that can be repaired before they become serious problems.

Can Thermally Sprayed Aluminum (TSA) Mitigate Corrosion of Carbon Steel in Carbon Capture and Storage (CCS) Environments?

NASA Astrophysics Data System (ADS)

Paul, S.; Syrek-Gerstenkorn, B.

2017-01-01

Transport of CO2 for carbon capture and storage (CCS) uses low-cost carbon steel pipelines owing to their negligible corrosion rates in dry CO2. However, in the presence of liquid water, CO2 forms corrosive carbonic acid. In order to mitigate wet CO2 corrosion, use of expensive corrosion-resistant alloys is recommended; however, the increased cost makes such selection economically unfeasible; hence, new corrosion mitigation methods are sought. One such method is the use of thermally sprayed aluminum (TSA), which has been used to mitigate corrosion of carbon steel in seawater, but there are concerns regarding its suitability in CO2-containing solutions. A 30-day test was carried out during which carbon steel specimens arc-sprayed with aluminum were immersed in deionized water at ambient temperature bubbled with 0.1 MPa CO2. The acidity (pH) and potential were continuously monitored, and the amount of dissolved Al3+ ions was measured after completion of the test. Some dissolution of TSA occurred in the test solution leading to nominal loss in coating thickness. Potential measurements revealed that polarity reversal occurs during the initial stages of exposure which could lead to preferential dissolution of carbon steel in the case of coating damage. Thus, one needs to be careful while using TSA in CCS environments.

Hazard of ultraviolet radiation emitted in gas metal arc welding of mild steel.

PubMed

Nakashima, Hitoshi; Utsunomiya, Akihiro; Takahashi, Jyunya; Fujii, Nobuyuki; Okuno, Tsutomu

2016-09-30

Ultraviolet radiation (UVR) emitted during arc welding frequently causes keratoconjunctivitis and erythema in the workplace. The degree of hazard from UVR exposure depends on the welding method and conditions. Therefore, it is important to identify the UVR levels present under various conditions. We experimentally evaluated the UVR levels emitted in gas metal arc welding (GMAW) of mild steel. We used both a pulsed welding current and a non-pulsed welding current. The shielding gases were 80% Ar + 20% CO 2 and 100% CO 2 . The effective irradiance defined in the American Conference of Governmental Industrial Hygienists guidelines was used to quantify the UVR hazard. The effective irradiance measured in this study was in the range of 0.51-12.9 mW/cm 2 at a distance of 500 mm from the arc. The maximum allowable exposure times at these levels are only 0.23-5.9 s/day. The following conclusions were made regarding the degree of hazard from UVR exposure during the GMAW of mild steel: (1) It is more hazardous at higher welding currents than at lower welding currents. (2) At higher welding currents, it is more hazardous when 80% Ar + 20% CO 2 is used as a shielding gas than when 100% CO 2 is used. (3) It is more hazardous for pulsed welding currents than for non-pulsed welding currents. (4) It appears to be very hazardous when metal transfer is the spray type. This study demonstrates that unprotected exposure to UVR emitted by the GMAW of mild steel is quite hazardous.

Hazard of ultraviolet radiation emitted in gas metal arc welding of mild steel

PubMed Central

Nakashima, Hitoshi; Utsunomiya, Akihiro; Takahashi, Jyunya; Fujii, Nobuyuki; Okuno, Tsutomu

2016-01-01

Objectives: Ultraviolet radiation (UVR) emitted during arc welding frequently causes keratoconjunctivitis and erythema in the workplace. The degree of hazard from UVR exposure depends on the welding method and conditions. Therefore, it is important to identify the UVR levels present under various conditions. Methods: We experimentally evaluated the UVR levels emitted in gas metal arc welding (GMAW) of mild steel. We used both a pulsed welding current and a non-pulsed welding current. The shielding gases were 80% Ar + 20% CO2 and 100% CO2. The effective irradiance defined in the American Conference of Governmental Industrial Hygienists guidelines was used to quantify the UVR hazard. Results: The effective irradiance measured in this study was in the range of 0.51-12.9 mW/cm2 at a distance of 500 mm from the arc. The maximum allowable exposure times at these levels are only 0.23-5.9 s/day. Conclusions: The following conclusions were made regarding the degree of hazard from UVR exposure during the GMAW of mild steel: (1) It is more hazardous at higher welding currents than at lower welding currents. (2) At higher welding currents, it is more hazardous when 80% Ar + 20% CO2 is used as a shielding gas than when 100% CO2 is used. (3) It is more hazardous for pulsed welding currents than for non-pulsed welding currents. (4) It appears to be very hazardous when metal transfer is the spray type. This study demonstrates that unprotected exposure to UVR emitted by the GMAW of mild steel is quite hazardous. PMID:27488036

Transverse-Weld Tensile Properties of a New Al-4Cu-2Si Alloy as Filler Metal

NASA Astrophysics Data System (ADS)

Sampath, K.

2009-12-01

AA2195, an Al-Cu-Li alloy in the T8P4 age-hardened condition, is a candidate aluminum armor for future combat vehicles, as this material offers higher static strength and ballistic protection than current aluminum armor alloys. However, certification of AA2195 alloy for armor applications requires initial qualification based on the ballistic performance of welded panels in the as-welded condition. Currently, combat vehicle manufacturers primarily use gas metal arc welding (GMAW) process to meet their fabrication needs. Unfortunately, a matching GMAW consumable electrode is currently not commercially available to allow effective joining of AA2195 alloy. This initial effort focused on an innovative, low-cost, low-risk approach to identify an alloy composition suitable for effective joining of AA2195 alloy, and evaluated transverse-weld tensile properties of groove butt joints produced using the identified alloy. Selected commercial off-the-shelf (COTS) aluminum alloy filler wires were twisted to form candidate twisted filler rods. Representative test weldments were produced using AA2195 alloy, candidate twisted filler rods and gas tungsten arc welding (GTAW) process. Selected GTA weldments produced using Al-4wt.%Cu-2wt.%Si alloy as filler metal consistently provided transverse-weld tensile properties in excess of 275 MPa (40 ksi) UTS and 8% El (over 25 mm gage length), thereby showing potential for acceptable ballistic performance of as-welded panels. Further developmental work is required to evaluate in detail GMAW consumable wire electrodes based on the Al-Cu-Si system containing 4.2-5.0 wt.% Cu and 1.6-2.0 wt.% Si.

On the toughness scatter in low alloy C-Mn steel samples fabricated using wire arc additive manufacturing

DOE PAGES

Sridharan, Niyanth S.; Noakes, Mark W.; Nycz, Andrzej; ...

2017-12-06

Low alloy carbon manganese (C-Mn) steel builds were fabricated using a wire based additive manufacturing system developed at Oak Ridge National Laboratory. Specimens were fabricated in the X,Y and Z direction and detailed mechanical testing was performed. The mechanical testing results showed a significant scatter in tensile ductility and significant variation in Charpy toughness. Further detailed microstructure characterization showed significant microstructural heterogeneity in builds fabricated in each direction. The scatter in mechanical properties was then rationalized based on the microstructural observations and the underlying changes in the local heat transfer conditions. Lastly, the results indicate that when fabricating parts usingmore » C-Mn low alloy steel welds the process parameters and tool path should be chosen such that the cooling rate from 800 °C to 500 °C is greater than 30 s to avoid formation of martensite austenite (MA) phases, which leads to toughness reductions.« less

Automatic hot wire GTA welding of pipe offers speed and increased deposition

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sykes, I.; Digiacomo, J.

1995-07-01

Heavy-wall pipe welding for the power and petrochemical industry must meet code requirements. Contractors strive to meet these requirements in the most productive way possible. The challenge put to orbital welding equipment manufacturers is to produce pipe welding equipment that cost-effectively produces code-quality welds. Orbital welding equipment using the GTA process has long produced outstanding quality results but has lacked the deposition rate to compete cost effectively with other manual and semiautomatic processes such as SMAW, FCAW and GMAW. In recent years, significant progress has been made with the use of narrow-groove weld joint designs to reduce weld joint volumemore » and improve welding times. Astro Arc Polysoude, an orbital welding equipment manufacturer based in Sun Valley, Calif., and Nantes, France, has combined the hot wire GTAW process with orbital welding equipment using a narrow-groove weld joint design. Field test results show this process and procedure is a good alternative for many heavy-wall-pipe welding applications.« less

Kite-flying: a unique but dangerous mode of electrical injury in children.

PubMed

Tiwari, V K; Sharma, D

1999-09-01

A retrospective study was conducted to evaluate the cause of a sudden rise in number of pediatric admissions with electrical injuries at our centre during the year 1998. In evaluating the cause, six out of twelve admissions were found to be related to kite-flying which is a popular sport during the months of June, July, August and September. In two out of six cases current travelled directly through the string of the kite. In two others, flame burns occured following ignition of clothing. Another patient had contact with wire through a metal rod. In the last case, arcing pulled the hand of the patient leading to direct contact with wire. The average burns size was approximately 31% body surface area (BSA), with all patients having burns over the palmar aspect of at least one hand. No patient required amputation for the injuries. In this article, attention has been focussed on the various modes of electrical injuries associated with kite-flying and some measures have been advised to avoid such accidents.

On the toughness scatter in low alloy C-Mn steel samples fabricated using wire arc additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sridharan, Niyanth S.; Noakes, Mark W.; Nycz, Andrzej

Low alloy carbon manganese (C-Mn) steel builds were fabricated using a wire based additive manufacturing system developed at Oak Ridge National Laboratory. Specimens were fabricated in the X,Y and Z direction and detailed mechanical testing was performed. The mechanical testing results showed a significant scatter in tensile ductility and significant variation in Charpy toughness. Further detailed microstructure characterization showed significant microstructural heterogeneity in builds fabricated in each direction. The scatter in mechanical properties was then rationalized based on the microstructural observations and the underlying changes in the local heat transfer conditions. Lastly, the results indicate that when fabricating parts usingmore » C-Mn low alloy steel welds the process parameters and tool path should be chosen such that the cooling rate from 800 °C to 500 °C is greater than 30 s to avoid formation of martensite austenite (MA) phases, which leads to toughness reductions.« less

Pseudo-Capacitors: SPPS Deposition and Electrochemical Analysis of α-MoO3 and Mo2N Coatings

NASA Astrophysics Data System (ADS)

Golozar, Mehdi; Chien, Ken; Lian, Keryn; Coyle, Thomas W.

2013-06-01

Solution precursor plasma spraying (SPPS) is a novel thermal spray process in which a solution precursor is injected into the high-temperature zone of a DC-arc plasma jet to allow solvent evaporation from the precursor droplets, solute precipitation, and precipitate pyrolysis prior to substrate impact. This investigation explored the potential of SPPS to fabricate α-MoO3 coatings with fine grain sizes, high porosity levels, and high surface area: characteristics needed for application as pseudo-capacitor electrodes. Since molybdenum nitride has shown a larger electrochemical stability window and higher specific area capacitance, the α-MoO3 deposits were subsequently converted into molybdenum nitride. A multistep heat-treatment procedure resulted in a topotactic phase-transformation mechanism, which retained the high surface area lath-shaped features of the original α-MoO3. The electrochemical behaviors of molybdenum oxide and molybdenum nitride deposits formed under different deposition conditions were studied using cyclic voltammetry to assess the influence of the resulting microstructure on the charge storage behavior and potential for use in pseudo-capacitors.

Synthesis of nanowires and nanoparticles of cubic aluminium nitride

NASA Astrophysics Data System (ADS)

Balasubramanian, C.; Godbole, V. P.; Rohatgi, V. K.; Das, A. K.; Bhoraskar, S. V.

2004-03-01

Nanostructures of cubic aluminium nitride were synthesized by DC arc-plasma-induced melting of aluminium in a nitrogen-argon ambient. The material flux ejected from the molten aluminium surface was found to react with nitrogen under highly non-equilibrium conditions and subsequently condense on a water-cooled surface to yield a mixture of nanowires and nanoparticles of crystalline cubic aluminium nitride. Both x-ray diffraction and electron diffraction measurements revealed that the as-synthesized nitrides adopted the cubic phase. Fourier transform infrared spectroscopy was used to understand the bonding configuration. Microstructural features of the synthesized material were best studied by transmission electron microscopy. From these analyses cubic aluminium nitride was found to be the dominating phase for both nanowires and nanoparticles synthesized at low currents. The typical particle size distribution was found to range over 15-80 nm, whereas the wires varied from 30 to 100 nm in diameter and 500 to 700 nm in length, depending upon the process parameters such as arc current and the nitrogen pressure. The reaction products inside the plasma zone were also obtained theoretically by minimization of free energy and the favourable zone temperature necessary for the formation of aluminium nitride was found to be {\\sim } 6000 K. Results are discussed in view of the highly non-equilibrium conditions that prevail during the arc-plasma synthesis.

Microstructure Evolution and Mechanical Behavior of 2219 Aluminum Alloys Additively Fabricated by the Cold Metal Transfer Process

PubMed Central

Fang, Xuewei; Li, Hui; Li, Chaolong; Lu, Bingheng

2018-01-01

In this research, four different welding arc modes including conventional cold metal transfer (CMT), CMT-Pulse (CMT-P), CMT-Advanced (CMT-ADV), and CMT pulse advanced (CMT-PADV) were used to deposit 2219-Al wire. The effects of different arc modes on porosity, pore size distribution, microstructure evolution, and mechanical properties were thoroughly investigated. The statistical analysis of the porosity and its size distribution indicated that the CMT-PADV process gave the smallest pore area percentage and pore aspect ratio, and had almost no larger pores. The results from optical microscopy, scanning electron microscopy, and fractographic morphology proved that uniform and fine equiaxed grains, evenly distributed Al2Cu second phase particles were formed during the CMT-PADV process. Furthermore, the X-ray diffraction test ascertained that the CMT-PADV sample had the smallest lattice parameter and the highest solute Cu content. Besides, the tensile strength could reach 283 MPa, the data scattering was the smallest, and the strength scattering of the sample in the horizontal direction was the shortest. In addition, the strength properties were nearly isotropic, with only 5 MPa difference in the vertical and horizontal directions. The above mentioned results indicated that the mechanical properties of 2219 aluminum alloy was improved using the CMT-PADV arc mode. PMID:29772708

Microstructure Evolution and Mechanical Behavior of 2219 Aluminum Alloys Additively Fabricated by the Cold Metal Transfer Process.

PubMed

Fang, Xuewei; Zhang, Lijuan; Li, Hui; Li, Chaolong; Huang, Ke; Lu, Bingheng

2018-05-16

In this research, four different welding arc modes including conventional cold metal transfer (CMT), CMT-Pulse (CMT-P), CMT-Advanced (CMT-ADV), and CMT pulse advanced (CMT-PADV) were used to deposit 2219-Al wire. The effects of different arc modes on porosity, pore size distribution, microstructure evolution, and mechanical properties were thoroughly investigated. The statistical analysis of the porosity and its size distribution indicated that the CMT-PADV process gave the smallest pore area percentage and pore aspect ratio, and had almost no larger pores. The results from optical microscopy, scanning electron microscopy, and fractographic morphology proved that uniform and fine equiaxed grains, evenly distributed Al₂Cu second phase particles were formed during the CMT-PADV process. Furthermore, the X-ray diffraction test ascertained that the CMT-PADV sample had the smallest lattice parameter and the highest solute Cu content. Besides, the tensile strength could reach 283 MPa, the data scattering was the smallest, and the strength scattering of the sample in the horizontal direction was the shortest. In addition, the strength properties were nearly isotropic, with only 5 MPa difference in the vertical and horizontal directions. The above mentioned results indicated that the mechanical properties of 2219 aluminum alloy was improved using the CMT-PADV arc mode.

Cathode degradation and erosion in high pressure arc discharges

NASA Technical Reports Server (NTRS)

Hardy, T. L.; Nakanishi, S.

1984-01-01

The various processes which control cathode erosion and degradation were identified and evaluated. A direct current arc discharge was established between electrodes in a pressure-controlled gas flow environment. The cathode holder was designed for easy testing of various cathode materials. The anode was a water cooled copper collector electrode. The arc was powered by a dc power supply with current and voltage regulated cross-over control. Nitrogen and argon were used as propellants and the materials used were two percent thoriated tungsten, barium oxide impregnated porous tungsten, pure tungsten and lanthanum hexaboride. The configurations used were cylindrical solid rods, wire bundles supported by hollow molybdenum tubes, cylindrical hollow tubes, and hollow cathodes of the type used in ion thrusters. The results of the mass loss tests in nitrogen indicated that pure tungsten eroded at a rate more than 10 times faster than the rates of the impregnated tungsten materials. It was found that oxygen impurities of less than 0.5 percent in the nitrogen increased the mass loss rate by a factor of 4 over high purity nitrogen. At power levels less than 1 kW, cathode size and current level did not significantly affect the mass loss rate. The hollow cathode was found to be operable in argon and in nitrogen only at pressures below 400 and 200 torr, respectively.

Control of exposure to hexavalent chromium concentration in shielded metal arc welding fumes by nano-coating of electrodes.

PubMed

Sivapirakasam, S P; Mohan, Sreejith; Santhosh Kumar, M C; Thomas Paul, Ashley; Surianarayanan, M

2017-04-01

Background Cr(VI) is a suspected human carcinogen formed as a by-product of stainless steel welding. Nano-alumina and nano-titania coating of electrodes reduced the welding fume levels. Objective To investigate the effect of nano-coating of welding electrodes on Cr(VI) formation rate (Cr(VI) FR) from a shielded metal arc welding process. Methods The core welding wires were coated with nano-alumina and nano-titania using the sol-gel dip coating technique. Bead-on plate welds were deposited on SS 316 LN plates kept inside a fume test chamber. Cr(VI) analysis was done using an atomic absorption spectrometer (AAS). Results A reduction of 40% and 76%, respectively, in the Cr(VI) FR was observed from nano-alumina and nano-titania coated electrodes. Increase in the fume level decreased the Cr(VI) FR. Discussion Increase in fume levels blocked the UV radiation responsible for the formation of ozone thereby preventing the formation of Cr(VI).

A droplet in the inter-electrode gap during gas metal arc welding

NASA Astrophysics Data System (ADS)

Nemchinsky, Valerian

2011-11-01

Electrical current flowing through a metallic droplet after its detachment from the wire anode during gas metal arc welding (GMAW) is considered. Although the droplet has much higher electrical conductivity compared with the conductivity of the surrounding plasma, current cannot enter the droplet freely since doing so demands igniting of the cathode spot responsible for electron emission. A new mechanism of current flow through a metallic droplet is suggested: one part of the droplet has a potential, which is slightly below the floating potential; this part of the droplet collects ions from the plasma. The remaining portion of the droplet has a potential difference, which is slightly above the floating one. The latter section collects electrons which recombine with the ions collected by the rest of the droplet's surface. The maximum electric current that can flow through the droplet is estimated. It is shown that this current is on the order of a few tens of amperes.

The mechanical properties of high speed GTAW weld and factors of nonlinear multiple regression model under external transverse magnetic field

NASA Astrophysics Data System (ADS)

Lu, Lin; Chang, Yunlong; Li, Yingmin; He, Youyou

2013-05-01

A transverse magnetic field was introduced to the arc plasma in the process of welding stainless steel tubes by high-speed Tungsten Inert Gas Arc Welding (TIG for short) without filler wire. The influence of external magnetic field on welding quality was investigated. 9 sets of parameters were designed by the means of orthogonal experiment. The welding joint tensile strength and form factor of weld were regarded as the main standards of welding quality. A binary quadratic nonlinear regression equation was established with the conditions of magnetic induction and flow rate of Ar gas. The residual standard deviation was calculated to adjust the accuracy of regression model. The results showed that, the regression model was correct and effective in calculating the tensile strength and aspect ratio of weld. Two 3D regression models were designed respectively, and then the impact law of magnetic induction on welding quality was researched.

Shielding Gas and Heat Input Effects on the Mechanical and Metallurgical Characterization of Gas Metal Arc Welding of Super Martensitic Stainless Steel (12Cr5Ni2Mo) Joints

NASA Astrophysics Data System (ADS)

Prabakaran, T.; Prabhakar, M.; Sathiya, P.

This paper deals with the effects of shielding gas mixtures (100% CO2, 100% Ar and 80 % Ar + 20% CO2) and heat input (3.00, 3.65 and 4.33kJ/mm) on the mechanical and metallurgical characteristics of AISI 410S (American Iron and Steel Institute) super martensitic stainless steel (SMSS) by gas metal arc welding (GMAW) process. AISI 410S SMSS with 1.2mm diameter of a 410 filler wire was used in this study. A detailed microstructural analysis of the weld region as well as the mechanical properties (impact, microhardness and tensile tests at room temperature and 800∘C) was carried out. The tensile and impact fracture surfaces were further analyzed through scanning electron microscope (SEM). 100% Ar shielded welds have a higher amount of δ ferrite content and due to this fact the tensile strength of the joints is superior to the other two shielded welds.

Experimental investigations on active cooling thermal protection structure of hydrocarbon-fueled scramjet combustor in arc heated facility

NASA Astrophysics Data System (ADS)

Jianqiang, Tu; Jinlong, Peng; Xianning, Yang; Lianzhong, Chen

2016-10-01

The active cooling thermal protection technology is the efficient method to resolve the long-duration work and reusable problems of hydrocarbon-fueled scramjet combustor, where worst thermo-mechanical loads occur. The fuel is passed through coolant channels adjacent to the heated surfaces to absorb heat from the heating exchanger panels, prior to injection into the combustor. The heating exchanger both cooled down the wall temperature of the combustor wall and heats and cracks the hydrocarbon fuel inside the panel to permit an easier combustion and satisfying combustion efficiency. The subscale active cooling metallic panels, with dimensions of 100×100 mm and different coolant channel sizes, have been tested under typical combustion thermal environment produced by arc heated Turbulent Flow Duct (TFD). The heat exchange ability of different coolant channel sizes has been obtained. The big-scale active cooling metallic panel, with dimensions of 100 × 750 mm and the coolant channel sizes of better heating exchange performance, has been made and tested in the big-scale arc heated TFD facility. The test results show that the local superheated ablation is easy to happen for the cooling fuel assigned asymmetrically in the bigscale active cooling metallic panel, and the cooling fuel rate can reduce 8%˜10% after spraying the Thermal Barrier Coating (TBC) in the heating surface.

High-Temperature Extensometry and PdCr Temperature-Compensated Wire Resistance Strain Gages Compared

NASA Technical Reports Server (NTRS)

1997-01-01

A detailed experimental evaluation is underway at the NASA Lewis Research Center to compare and contrast the performance of the PdCr/Pt dual-element temperature-compensated wire resistance strain gage with that of conventional high-temperature extensometry. The advanced PdCr gage, developed by researchers at Lewis, exhibits desirable properties and a relatively small and repeatable apparent strain to 800 C. This gage represents a significant advance in technology because existing commercial resistance strain gages are not reliable for quasi-static strain measurements above approx. 400 C. Various thermal and mechanical loading spectra are being applied by a high-temperature thermomechanical uniaxial testing system to evaluate the two strain-measurement systems. This is being done not only to compare and contrast the two strain sensors, but also to investigate the applicability of the PdCr strain gage to the coupon-level specimen testing environment typically employed when the high-temperature mechanical behavior of structural materials is characterized. Strain measurement capabilities to 800 C are being investigated with a nickel-base superalloy, Inconel 100 (IN 100), substrate material and application to TMC's is being examined with the model system, SCS-6/Ti-15-3. Furthermore, two gage application techniques are being investigated in the comparison study: namely, flame-sprayed and spot welding. The apparent strain responses of both the weldable and flame-sprayed PdCr wire strain gages were found to be cyclically repeatable on both IN 100 and SCS-6/Ti-15-3 [0]_8. In general, each gage exhibited some uniqueness with respect to apparent strain behavior. Gages mounted on the IN 100 specimens tended to show a repeatable apparent strain within the first few cycles, because the thermal response of IN 100 was stable. This was not the case, however, for the TMC specimens, which typically required several thermal cycles to stabilize the thermal strain response. Thus, progressive changes in the apparent strain behavior were corroborated by the extensometer, which unlike the mounted gage can distinguish quantitative changes in the material's thermal strain response. One specimen was instrumented with both a fixed and floating gage. From the difference in output of these two gages, the thermal expansion strains were calculated. These data, which are given in the figure, show excellent agreement with the values measured by the high-temperature extensometry.

Report of the Seasat Failure Review Board

NASA Technical Reports Server (NTRS)

Lundin, Bruce T.

1978-01-01

The Seasat spacecraft failed on October 9, 1978, after satisfactory operation in orbit for 105 days, as a result of a loss of electrical power in the Agena bus that was used as a part of the spacecraft. This loss of power was caused by a massive and progressive short in one of the slip ring assemblies that was used to connect the rotating solar arrays into the power subsystem. The most likely cause of this short was the initiation of an arc between adjacent slip ring brush assemblies. The triggering mechanism of this arc could have been either a wire-to-brush assembly contact, a brush-to-brush contact, or a momentary short caused by a contaminant that bridged internal components of opposite electrical polarity. The slip ring assembly, as used in the Seasat spacecraft, was connected into the power subsystem in such a way that most of the adjacent brush assemblies were of opposite electrical polarity. This wiring arrangement, together with the congested nature of the design itself, made the Seasat slip ring assembly a unique, first-of-a-kind component that was particularly prone to shorting. The possibility of slip ring failures resulting from placing opposite electrical polarities on adjacent brush assemblies was known at least as early-as the summer of 1977 to other projects within the contractor's organization. Furthermore, failures of slip ring assemblies due to shorting between brushes had been experienced by the prime contractor on slip ring assemblies used by other programs. That the Seasat organization was not fully aware of these potential failure modes was due to a breakdown in communication within the contractor's organization.

Design for low-cost gas metal arc weld-based aluminum 3-D printing

NASA Astrophysics Data System (ADS)

Haselhuhn, Amberlee S.

Additive manufacturing, commonly known as 3-D printing, has the potential to change the state of manufacturing across the globe. Parts are made, or printed, layer by layer using only the materials required to form the part, resulting in much less waste than traditional manufacturing methods. Additive manufacturing has been implemented in a wide variety of industries including aerospace, medical, consumer products, and fashion, using metals, ceramics, polymers, composites, and even organic tissues. However, traditional 3-D printing technologies, particularly those used to print metals, can be prohibitively expensive for small enterprises and the average consumer. A low-cost open-source metal 3-D printer has been developed based upon gas metal arc weld (GMAW) technology. Using this technology, substrate release mechanisms have been developed, allowing the user to remove a printed metal part from a metal substrate by hand. The mechanical and microstructural properties of commercially available weld alloys were characterized and used to guide alloy development in 4000 series aluminum-silicon alloys. Wedge casting experiments were performed to screen magnesium, strontium, and titanium boride alloying additions in hypoeutectic aluminum-silicon alloys for their properties and the ease with which they could be printed. Finally, the top performing alloys, which were approximately 11.6% Si modified with strontium and titanium boride were cast, extruded, and drawn into wire. These wires were printed and the mechanical and microstructural properties were compared with those of commercially available alloys. This work resulted in an easier-to-print aluminum-silicon-strontium alloy that exhibited lower porosity, equivalent yield and tensile strengths, yet nearly twice the ductility compared to commercial alloys.

Magnetic-Field-Response Measurement-Acquisition System

NASA Technical Reports Server (NTRS)

Woodward, Stanley E.; Shams, Qamar A.; Fox, Robert L.; Taylor, Bryant D.

2006-01-01

A measurement-acquisition system uses magnetic fields to power sensors and to acquire measurements from sensors. The system alleviates many shortcomings of traditional measurement-acquisition systems, which include a finite number of measurement channels, weight penalty associated with wires, use limited to a single type of measurement, wire degradation due to wear or chemical decay, and the logistics needed to add new sensors. Eliminating wiring for acquiring measurements can alleviate potential hazards associated with wires, such as damaged wires becoming ignition sources due to arcing. The sensors are designed as electrically passive inductive-capacitive or passive inductive-capacitive-resistive circuits that produce magnetic-field-responses. One or more electrical parameters (inductance, capacitance, and resistance) of each sensor can be variable and corresponds to a measured physical state of interest. The magnetic-field- response attributes (frequency, amplitude, and bandwidth) of the inductor correspond to the states of physical properties for which each sensor measures. For each sensor, the measurement-acquisition system produces a series of increasing magnetic-field harmonics within a frequency range dedicated to that sensor. For each harmonic, an antenna electrically coupled to an oscillating current (the frequency of which is that of the harmonic) produces an oscillating magnetic field. Faraday induction via the harmonic magnetic fields produces an electromotive force and therefore a current in the sensor. Once electrically active, the sensor produces its own harmonic magnetic field as the inductor stores and releases magnetic energy. The antenna of the measurement- acquisition system is switched from a transmitting to a receiving mode to acquire the magnetic-field response of the sensor. The rectified amplitude of the received response is compared to previous responses to prior transmitted harmonics, to ascertain if the measurement system has detected a response inflection. The "transmit-receive-compare" of sequential harmonics is repeated until the inflection is identified. The harmonic producing the amplitude inflection is the sensor resonant frequency. Resonant frequency and response amplitude are stored and then correlated to calibration data.

Rail damage in a solid-armature rail gun. Final report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Brassard, T.; Homan, C.G.

1987-12-01

Plasma-arc-drive rail guns operate by forming a high-temperature plasma behind the projectile using a thin metal fuze. These systems achieve the highest projectile velocities (about 12 km /sec), since the driving force includes a substantial plasma pressure as well as the electromagnetic or Lorentz force. Unfortunately, severe rail damage occurs primarily from the intense temperatures generated by the plasma arc and the wiping motion of the armature itself. The solid-armature gun replaces the plasma armature with a conducting metal armature. Since the plasma arcing is reduced or eliminated, the projectiles are accelerated mainly by the Lorentz force. Thus, solid armaturemore » rail guns operate at lower projectile velocities. The important tradeoff is that there is a substantial reduction in rail damage for metal armature projectiles. The elimination of the plasma force limits projectile velocities in the metal-armature rail guns. A more-subtle limit is the speed at which the commutation process can take place. Although the latter limit is still not well understood, experimental evidence indicates a commutation limit may occur near 6 to 7 km/sec. This velocity limit is still attractive for Army tactical missions for rail guns. The actual rail damage occurring with two types of metal armatures, wire brush contactors and monolithic metal contactors, and new developments in barrel technology, such as superconducting augmentation, are presented in this report.« less

ROBUST hot wire probe efficiency for total water content measurements in glaciated conditions

NASA Astrophysics Data System (ADS)

Leroy, Delphine; Lilie, Lyle; Weber, Marc; Schwarzenboeck, Alfons; Strapp, J. Walter

2017-04-01

During the two High Altitude Ice Crystals (HAIC, Dezitter et al. 2013)/High Ice Water Content (HIWC, Strapp et al., 2016a) international flight campaigns that investigated deep convection in the tropics, the French Falcon 20 research aircraft was equipped with two different devices measuring the Total Water Content (TWC): - the IKP-2 (Isokinetic Probe, Davison et al. 2008, 2016), - and the hot wire ROBUST probe (Strapp et al. 2008; Grandin et al. 2014). The IKP-2 probe is an evaporator that has been specifically designed to measure high ice water content (Strapp et al. 2016b) with a collection efficiency near unity. It has undergone extensive performance assessment in liquid and glaciated conditions in several wind tunnels. The Robust probe was initially developed by Science Engineering Associates to estimate high ice water content in a high speed wind tunnel, in harsh conditions where other hot-wires had been observed to suffer failures. It was known at the outset that, like other hot-wire TWC probes, it would measure only a quasi-constant fraction of the true ice water content. Early wind tunnel and flight experience with the ROBUST probe revealed that this fraction was the order of 40% for ice crystals. During the HAIC/HIWC campaigns (Leroy et al. 2016, 2017), supercooled liquid water conditions were documented according to a detailed analysis of a Rosemount Ice detector (RICE) and a Cloud Droplet Probe (CDP) measurements, and were found to be rare. Thus, the HAIC/HIWC dataset represents a unique opportunity to study in more detail the ROBUST efficiency in glaciated conditions, using the IKP-2 values as a comparative reference. Comparison of IKP-2 and ROBUST measurements will show that the ROBUST behavior differs between low (below 1.5 g/m3) and high (above 2 g/m3) ice content conditions and is also sensitive to temperature. The sensitivity of the ROBUST collection efficiency to ice particles size could also be explored as optical imaging probes were part of the airborne instrument package but no clear trend has been highlighted for the moment. References : Davison, C., J. MacLeod, J. Strapp, and D. Buttsworth, 2008: Isokinetic Total Water Content Probe in a Naturally Aspirating Configuration: Initial Aerodynamic Design and Testing. 46th AIAA Aerospace Sciences Meeting and Exhibit, American Institute of Aeronautics and Astronautics http://arc.aiaa.org/doi/abs/10.2514/6.2008-435 (Accessed February 9, 2015). Davison, C. R., J. W. Strapp, L. E. Lilie, T. P. Ratvasky, and C. Dumont, 2016: Isokinetic TWC Evaporator Probe: Calculations and Systemic Error Analysis. American Institute of Aeronautics and Astronautics http://arc.aiaa.org/doi/10.2514/6.2016-4060 (Accessed July 29, 2016). Dezitter, F., A. Grandin, J.-L. Brenguier, F. Hervy, H. Schlager, P. Villedieu, and G. Zalamansky, 2013: HAIC - High Altitude Ice Crystals. 5th AIAA Atmospheric and Space Environments Conference, American Institute of Aeronautics and Astronautics http://arc.aiaa.org/doi/abs/10.2514/6.2013-2674 (Accessed February 9, 2015). Grandin, A., J.-M. Merle, M. Weber, J. Strapp, A. Protat, and P. King, 2014: AIRBUS Flight Tests in High Total Water Content Regions. American Institute of Aeronautics and Astronautics http://arc.aiaa.org/doi/abs/10.2514/6.2014-2753 (Accessed March 8, 2016). Leroy, D., and Coauthors, 2016: HAIC/HIWC field campaigns - Specific findings on ice crystals characteristics in high ice water content cloud regions. American Institute of Aeronautics and Astronautics http://arc.aiaa.org/doi/10.2514/6.2016-4056 (Accessed January 10, 2017). Leroy, D., and Coauthors, 2017: Ice Crystal Sizes in High Ice Water Content Clouds. Part II: Statistics of Mass Diameter Percentiles in Tropical Convection Observed during the HAIC/HIWC Project. J. Atmospheric Ocean. Technol., 34, 117-136, doi:10.1175/JTECH-D-15-0246.1. Strapp, J. W., J. MacLeod, and L. Lilie, 2008: Calibration of ice water content in a wind tunnel/engine test cell facility. 15th Intl. Conf. on Cloud and Precipitation http://cabernet.atmosfcu.unam.mx/ICCP-2008/abstracts/Program_on_line/Poster_13/StrappEtAl-extended.pdf (Accessed April 25, 2016). Strapp, J. W., L. E. Lilie, T. P. Ratvasky, C. R. Davison, and C. Dumont, 2016b: Isokinetic TWC Evaporator Probe: Development of the IKP2 and Performance Testing for the HAIC-HIWC Darwin 2014 and Cayenne Field Campaigns. American Institute of Aeronautics and Astronautics http://arc.aiaa.org/doi/10.2514/6.2016-4059 (Accessed July 29, 2016). Strapp, J. W., G. A. Isaac. A. Korolev, T. Ratvasky, R. Potts, P. May, A. Protat, P. Minnis, A. Ackerman, A. Fridlind, J. Haggerty, and J. Riley, 2016a: The High Ice Water Content (HIWC) Study of deep convective clouds: Science and technical plan. FAA Rep. DOT/FAA/TC-14/31, available at http://www.tc.faa.gov/its/worldpac/techrpt/tc14-31.pdf. 105 pgs.

Evaluation of iron aluminide weld overlays for erosion - corrosion resistant boiler tube coatings in low NO{sub x} boilers

DOE Office of Scientific and Technical Information (OSTI.GOV)

DuPont, J.N.; Banovic, S.W.; Marder, A.R.

1996-08-01

Low NOx burners are being installed in many fossil fired power plants in order to comply with new Clean Air Regulations. Due to the operating characteristics of these burners, boiler tube sulfidation corrosion is often enhanced and premature tube failures can occur. Failures due to oxidation and solid particle erosion are also a concern. A program was initiated in early 1996 to evaluate the use of iron aluminide weld overlays for erosion/corrosion protection of boiler tubes in Low NOx boilers. Composite iron/aluminum wires will be used with the Gas Metal Arc Welding (GMAW) process to prepare overlays on boiler tubesmore » steels with aluminum contents from 8 to 16wt%. The weldability of the composite wires will be evaluated as a function of chemical composition and welding parameters. The effect of overlay composition on corrosion (oxidation and sulfidation) and solid particle erosion will also be evaluated. The laboratory studies will be complemented by field exposures of both iron aluminide weld overlays and co-extruded tubing under actual boiler conditions.« less

A 18 m 2 cylindrical tracking detector made of 2.6 m long, stereo mylar straw tubes with 100 μm resolution

NASA Astrophysics Data System (ADS)

Benussi, L.; Bertani, M.; Bianco, S.; Fabbri, F. L.; Gianotti, P.; Giardoni, M.; Ghezzo, A.; Guaraldo, C.; Lanaro, A.; Locchi, P.; Lu, J.; Lucherini, V.; Mecozzi, A.; Pace, E.; Passamonti, L.; Qaisar, N.; Ricciardi, A.; Sarwar, S.; Serdyouk, V.; Trasatti, L.; Volkov, A.; Zia, A.

1998-12-01

An array of 2424 2.6 m-long, 15 mm-diameter mylar straw tubes, arranged in two axial and four stereo layers, has been assembled. The array covers a cylindrical tracking surface of 18 m 2 and provides coordinate measurement in the drift direction and along the wire. A correction of the systematic effects which are introduced by gravitational sag and electrostatics, thus dominating the detector performance especially with long straws, allows to determine wire position from drift-time distribution. The correction has been applied to reach a space resolution of 40 μm with DME, 100 μm with Ar+C 2H 6, and 100-200 μm with CO 2. Such a resolution is the best ever obtained for straws of these dimensions. A study of the gas leakage for the straw system has been performed, and results are reported. The array is being commissioned as a subdetector of the FINUDA spectrometer, and tracking performances are being studied with cosmic rays.

[Hygienic evaluation of new welding processes and welding materials].

PubMed

Gorban', L N

1990-01-01

The possibility of contaminating the breathing air zone with hazardous substances in manual and semi-automated welding increases with the intensity of their formation in the arc zone. This necessitates more comprehensive data on both the specific excreta and the formation intensity of the most hazardous substances, such as hard and gaseous compounds of welding aerosols, with due account of the welding regimen used and electrode diameter, wires, etc. When calculating the effectiveness of both local and general ventilation systems in welding shops, a possibility of a specific one-way hazardous action of some chemical substances (e.g. chromium, fluorine, etc.) should be taken into account.

Investigation of Electromagnetic Field Threat to Fuel Tank Wiring of a Transport Aircraft

NASA Technical Reports Server (NTRS)

Ely, Jay J.; Nguyen, Truong X.; Dudley, Kenneth L.; Scearce, Stephen A.; Beck, Fred B.; Deshpande, Manohar D.; Cockrell, C. R.

2000-01-01

National Transportation Safety Board investigators have questioned whether an electrical discharge in the Fuel Quantity Indication System (FQIS) may have initiated the TWA-800 center wing tank explosion. Because the FQIS was designed to be incapable of producing such a discharge on its own, attention has been directed to mechanisms of outside electromagnetic influence. To support the investigation, the NASA Langley Research Center was tasked to study the potential for radiated electromagnetic fields from external radio frequency (RF) transmitters and passenger carried portable electronic devices (PEDs) to excite the FQIS enough to cause arcing, sparking or excessive heating within the fuel tank.

Laser speckle velocimetry for robot manufacturing

NASA Astrophysics Data System (ADS)

Charrett, Thomas O. H.; Bandari, Yashwanth K.; Michel, Florent; Ding, Jialuo; Williams, Stewart W.; Tatam, Ralph P.

2017-06-01

A non-contact speckle correlation sensor for the measurement of robotic tool speed is presented for use in robotic manufacturing and is capable of measuring the in-plane relative velocities between a robot end-effector and the workpiece or other surface. The sensor performance was assessed in the laboratory with the sensor accuracies found to be better than 0:01 mm/s over a 70 mm/s velocity range. Finally an example of the sensors application to robotic manufacturing is presented where the sensor was applied to tool speed measurement for path planning in the wire and arc additive manufacturing process using a KUKA KR150 L110/2 industrial robot.

Contribution of precipitate on migrated grain boundaries to ductility-dip cracking in Alloy 625 weld joints

NASA Astrophysics Data System (ADS)

Lee, Dong Jin; Kim, Youn Soo; Shin, Yong Taek; Jeon, Eon Chan; Lee, Sang Hwa; Lee, Hyo-Jong; Lee, Sung Keun; Lee, Jun Hee; Lee, Hae Woo

2010-10-01

We investigated the crack properties in Alloy 625 weld metals and their characteristics using experimentally designed filler wires fabricated by varying the niobium and manganese contents in the flux with the shield metal arc welding (SMAW) process. The fast diffusivity of niobium on the migrated grain boundary (MGB) under strong restraint tensile stress, which was induced by the hardened matrix in weld metal containing high niobium and manganese, accelerated the growth of niobium carbide (NbC) in multipass deposits. Coalescence of microvoids along with incoherent NbC and further propagation induced ductility-dip cracking (DDC) on MGB.

Piercing mandrel strengthening by surfacing with nickel aluminide-based alloy

NASA Astrophysics Data System (ADS)

Zorin, I. V.; Dubtsov, Yu N.; Sokolov, G. N.; Artem'ev, A. A.; Lysak, V. I.; Elsukov, S. N.

2017-02-01

Electrode composite wire (CW) was used for argon-arc surfacing of a thermal-resisting nickel aluminide-based alloy (Ni-Al-Cr-W-Mo-Ta system) on the butt-end surface of the non-water-cooled piercing mandrel. It was shown that multipassing surfacing forms a defect-free deposited metal based on the γ’-Ni3Al phase of various structural origins. Using high-temperature sclerometry and thermal fatigue testing methods, the metal deposited with CW containing ultrafine particle of 0.3-0.4 % wt. WC carbide features increased resistance to thermal and force effects at temperatures up to 1200 °C.

Characterization and Properties of Micro-arc Composite Ceramic Coatings on Magnesium Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Long; Jiang, Bailing; Ge, Yanfeng

2013-05-21

Magnesium alloys are of growing interest for many industrial applications due to their favorable strength-to-weight ratio and excellent cast ability. However, one of the limiting factors in the use of magnesium on production vehicles is its poor corrosion resistance. Micro-arc Composite Ceramic (MCC) coatings on AZ91D magnesium alloys were prepared in combination with Micro-arc Oxidation (MAO) and electrophoresis technologies. The microstructure, corrosion resistance, abrasion resistance, stone impact resistance, thermal shock resistance and adhesion of MCC coating were studied, respectively. The surface and cross-section morphologies of MAO and MCC coating showed that the outer organic coating filled the holes on themore » surface of the MAO coating. It acted as a shelter on the MAO coating surface when the MCC coatings were exposed to corrosive environments. The corrosion resistance of the MCC coating was characterized by a copper-accelerated acetic acid salt spray test. The testing results showed that the creep back from scribe lines was less than 1mm and completely fit the evaluation standard. The composite structure of the MCC coating vastly improved the corrosion resistance of Mg alloys. According to testing standards, the resistance to abrasion, stone impact resistance, thermal shock resistance and adhesion of MCC coatings completely met the evaluation standard requirements. The MCC coated AZ91D magnesium alloys possessed excellent properties; this is a promising corrosion and wear resistance surface treatment technology on magnesium alloys for production vehicles.« less

Synthesis of single-walled carbon nanotubes and graphene composite in arc for ultracapacitors

NASA Astrophysics Data System (ADS)

Li, Jian; Cheng, Xiaoqian; Shashurin, Alexey; Keidar, Michael

2012-10-01

Arc discharge supported by the erosion of graphite anode is considered as one of the most practical and efficient methods to synthesize various carbon nanostructures such as single-walled carbon nanotubes (SWCNT) and graphene with minimal defects and large yield due to the relatively high synthesis temperature and eco-friendly growth mechanism. By introducing a non-uniform magnetic field during synthesis process, large-scale graphene and high-purity SWCNT can be obtained in one step. In addition, the yield of graphene can be controlled by external parameters, such as the type and pressure of buffer gas, the temperature of substrate, and so on. Possessing the properties of highly accessible surface area and good electrical conductivity, the composite of graphene and SWCNT are promising nanomaterials for the electrodes of ultracapacitor, which can store electric energy with high level of capacitance. In this work, we fabricated electrodes of ultracapacitor based on nanostructures composite by wire-wound rod coating method, characterized them by SEM, EDX and Raman spectroscopy, and tested the performance by a potentiostat/galvanostat.

Bone bonding strength of diamond-structured porous titanium-alloy implants manufactured using the electron beam-melting technique.

PubMed

Hara, Daisuke; Nakashima, Yasuharu; Sato, Taishi; Hirata, Masanobu; Kanazawa, Masayuki; Kohno, Yusuke; Yoshimoto, Kensei; Yoshihara, Yusuke; Nakamura, Akihiro; Nakao, Yumiko; Iwamoto, Yukihide

2016-02-01

The present study examined the bone bonding strength of diamond-structured porous titanium-alloy (Porous-Ti-alloy) manufactured using the electron beam-melting technique in comparison with fiber mesh-coated or rough-surfaced implants. Cylindrical implants with four different pore sizes (500, 640, 800, and 1000μm) of Porous-Ti-alloy, titanium fiber mesh (FM), and surfaces roughened by titanium arc spray (Ti-spray) were implanted into the distal femur of rabbits. Bone bonding strength and histological bone ingrowth were evaluated at 4 and 12weeks after implantation. The bone bonding strength of Porous-Ti-alloy implants (640μm pore size) increased over time from 541.4N at 4weeks to 704.6N at 12weeks and was comparable to that of FM and Ti-spray implants at both weeks. No breakage of the porous structure after mechanical testing was found with Porous-Ti-alloy implants. Histological bone ingrowth that increased with implantation time occurred along the inner structure of Porous-Ti-alloy implants. There was no difference in bone ingrowth in Porous-Ti-alloy implants with pore sizes among 500, 640, and 800μm; however, less bone ingrowth was observed with the 1000μm pore size. These results indicated Porous-Ti-alloy implants with pore size under 800μm provided biologically active and mechanically stable surface for implant fixation to bone, and had potential advantages for weight bearing orthopedic implants such as acetabular cups. Copyright © 2015 Elsevier B.V. All rights reserved.

Plasma spray nozzle with low overspray and collimated flow

NASA Technical Reports Server (NTRS)

Beason, Jr., George P. (Inventor); McKechnie, Timothy N. (Inventor); Power, Christopher A. (Inventor)

1996-01-01

An improved nozzle for reducing overspray in high temperature supersonic plasma spray devices comprises a body defining an internal passageway having an upstream end and a downstream end through which a selected plasma gas is directed. The nozzle passageway has a generally converging/diverging Laval shape with its upstream end converging to a throat section and its downstream end diverging from the throat section. The upstream end of the passageway is configured to accommodate a high current cathode for producing an electrical arc in the passageway to heat and ionize the gas flow to plasma form as it moves along the passageway. The downstream end of the nozzle is uniquely configured through the methodology of this invention to have a contoured bell-shape that diverges from the throat to the exit of the nozzle. Coating material in powder form is injected into the plasma flow in the region of the bell-shaped downstream end of the nozzle and the powder particles become entrained in the flow. The unique bell shape of the nozzle downstream end produces a plasma spray that is ideally expanded at the nozzle exit and thus virtually free of shock phenomena, and that is highly collimated so as to exhibit significantly reduced fanning and diffusion between the nozzle and the target. The overall result is a significant reduction in the amount of material escaping from the plasma stream in the form of overspray and a corresponding improvement in the cost of the coating operation and in the quality and integrity of the coating itself.

Remote Neural Pendants In A Welding-Control System

NASA Technical Reports Server (NTRS)

Venable, Richard A.; Bucher, Joseph H.

1995-01-01

Neural network integrated circuits enhance functionalities of both remote terminals (called "pendants") and communication links, without necessitating installation of additional wires in links. Makes possible to incorporate many features into pendant, including real-time display of critical welding parameters and other process information, capability for communication between technician at pendant and host computer or technician elsewhere in system, and switches and potentiometers through which technician at pendant exerts remote control over such critical aspects of welding process as current, voltage, rate of travel, flow of gas, starting, and stopping. Other potential manufacturing applications include control of spray coating and of curing of composite materials. Potential nonmanufacturing uses include remote control of heating, air conditioning, and lighting in electrically noisy and otherwise hostile environments.

Evaluation of Thermal Control Coatings for Flexible Ceramic Thermal Protection Systems

NASA Technical Reports Server (NTRS)

Kourtides, Demetrius; Carroll, Carol; Smith, Dane; Guzinski, Mike; Marschall, Jochen; Pallix, Joan; Ridge, Jerry; Tran, Duoc

1997-01-01

This report summarizes the evaluation and testing of high emissivity protective coatings applied to flexible insulations for the Reusable Launch Vehicle technology program. Ceramic coatings were evaluated for their thermal properties, durability, and potential for reuse. One of the major goals was to determine the mechanism by which these coated blanket surfaces become brittle and try to modify the coatings to reduce or eliminate embrittlement. Coatings were prepared from colloidal silica with a small percentage of either SiC or SiB6 as the emissivity agent. These coatings are referred to as gray C-9 and protective ceramic coating (PCC), respectively. The colloidal solutions were either brushed or sprayed onto advanced flexible reusable surface insulation blankets. The blankets were instrumented with thermocouples and exposed to reentry heating conditions in the Ames Aeroheating Arc Jet Facility. Post-test samples were then characterized through impact testing, emissivity measurements, chemical analysis, and observation of changes in surface morphology. The results show that both coatings performed well in arc jet tests with backface temperatures slightly lower for the PCC coating than with gray C-9. Impact testing showed that the least extensive surface destruction was experienced on blankets with lower areal density coatings.

RFID and Memory Devices Fabricated Integrally on Substrates

NASA Technical Reports Server (NTRS)

Schramm, Harry F.

2004-01-01

Electronic identification devices containing radio-frequency identification (RFID) circuits and antennas would be fabricated integrally with the objects to be identified, according to a proposal. That is to say, the objects to be identified would serve as substrates for the deposition and patterning of the materials of the devices used to identify them, and each identification device would be bonded to the identified object at the molecular level. Vacuum arc vapor deposition (VAVD) is the NASA derived process for depositing layers of material on the substrate. This proposal stands in contrast to the current practice of fabricating RFID and/or memory devices as wafer-based, self-contained integrated-circuit chips that are subsequently embedded in or attached to plastic cards to make smart account-information cards and identification badges. If one relies on such a chip to store data on the history of an object to be tracked and the chip falls off or out of the object, then one loses both the historical data and the means to track the object and verify its identity electronically. Also, in contrast is the manufacturing philosophy in use today to make many memory devices. Today s methods involve many subtractive processes such as etching. This proposal only uses additive methods, building RFID and memory devices from the substrate up in thin layers. VAVD is capable of spraying silicon, copper, and other materials commonly used in electronic devices. The VAVD process sprays most metals and some ceramics. The material being sprayed has a very strong bond with the substrate, whether that substrate is metal, ceramic, or even wood, rock, glass, PVC, or paper. An object to be tagged with an identification device according to the proposal must be compatible with a vacuum deposition process. Temperature is seldom an issue as the substrate rarely reaches 150 F (66 C) during the deposition process. A portion of the surface of the object would be designated as a substrate for the deposition of the device. By use of a vacuum arc vapor deposition apparatus, a thin electrically insulating film would first be deposited on the substrate. Subsequent layers of materials would then be deposited and patterned by use of known integrated-circuit fabrication techniques. The total thickness of the deposited layers could be much less than the 100- m thickness of the thinnest state-of-the-art self-contained microchips. Such a thin deposit could be readily concealed by simply painting over it. Both large vacuum chambers for production runs and portable hand-held devices for in situ applications are available.

An investigation of fibrogenic and other toxic effects of arc-welding fume particles deposited in the rat lung.

PubMed

Hicks, R; Al-Shamma, K J; Lam, H F; Hewitt, P J

1983-12-01

Lung burdens of deposited particles from fumes generated by arc-welding were established in rats by single inhalation exposures, repeated intermittent exposure or by intratracheal injection. Fumes from manual metal arc-welding using flux-coated mild-steel rods (MMA-MS) were compared with those from metal inert-gas welding with stainless steel wire (MIG-SS). After initial rapid clearance of deposited material from the lungs, persistent residual deposits remained. Such residues resulting from single inhalation were small and confined mainly to peribronchial accumulations in macrophage clusters. Deposits remaining after repeated inhalation were larger and more widespread. Intratracheal administration (50 mg) established massive residual deposits, giving nodular accumulations in peribronchial, subpleural and perivascular sites, with substantial alveolar parenchymal involvement. Deposits from both types of fumes contained predominantly iron. Particles from stainless steel also contained chromium, but concentrations of this element were low in deposits from MMA-MS fumes. MMA-MS deposits contained silica, probably amorphous. Long-term studies (up to 450 days) attempted to detect evidence of fibrosis resulting from particle burdens. Low-grade collagen fibre layers developed at margins of MMA-MS nodules. Diffuse reticulin fibre networks occurred within MIG-SS aggregates. Tissue hydroxyproline levels were increased (doubled) in lungs with intratracheal burdens of MMA-MS particles, but no significant increases resulted from MIG-SS. The major lesions were nodular aggregates of particle-laden macrophages with giant-cell formation, and alveolar epithelial thickening with atelectasis.

The PIX-2 experiment: An overview

NASA Astrophysics Data System (ADS)

Purvis, C. K.

1985-03-01

The second Plasma Interactions Experiment (PIX-2) was launched in January 1983 as a piggyback on the second stage of the Delta launch vehicle that carried IRAS into orbit. Placed in a 870 km circular polar orbit, it returned 18 hrs of data on the plasma current collection and arcing behavior of solar arrays biased to +/-1000 V in steps. The four 500 sq cm solar array segments were biased singly and in combinations. In addition to the array segments PIX-2 carried a Sun sensor, a Langmuir probe to measure electron currents, and a hot-wire filament electron emitter to control vehicle potential during positive array bias sequences. The PIX-2 experiment is reviewed from program and operational perspectives.

Measurement of atomic Stark parameters of many Mn I and Fe I spectral lines using GMAW process

NASA Astrophysics Data System (ADS)

Zielinska, S.; Pellerin, S.; Dzierzega, K.; Valensi, F.; Musiol, K.; Briand, F.

2010-11-01

The particular character of the welding arc working in pure argon, whose emission spectrum consists of many spectral lines strongly broadened by the Stark effect, has allowed measurement, sometimes for the first time, of the Stark parameters of 15 Mn I and 10 Fe I atomic spectral lines, and determination of the dependence on temperature of normalized Stark broadening in Ne = 1023 m-3 of the 542.4 nm atomic iron line. These results show that special properties of the MIG plasma may be useful in this domain because composition of the wire-electrode may be easily adapted to the needs of an experiment.

DIAC object recognition system

NASA Astrophysics Data System (ADS)

Buurman, Johannes

1992-03-01

This paper describes the object recognition system used in an intelligent robot cell. It is used to recognize and estimate pose and orientation of parts as they enter the cell. The parts are mostly metal and consist of polyhedral and cylindrical shapes. The system uses feature-based stereo vision to acquire a wireframe of the observed part. Features are defined as straight lines and ellipses, which lead to a wireframe of straight lines and circular arcs (the latter using a new algorithm). This wireframe is compared to a number of wire frame models obtained from the CAD database. Experimental results show that image processing hardware and parallelization may add considerably to the speed of the system.

A generalized method for multiple robotic manipulator programming applied to vertical-up welding

NASA Technical Reports Server (NTRS)

Fernandez, Kenneth R.; Cook, George E.; Andersen, Kristinn; Barnett, Robert Joel; Zein-Sabattou, Saleh

1991-01-01

The application is described of a weld programming algorithm for vertical-up welding, which is frequently desired for variable polarity plasma arc welding (VPPAW). The Basic algorithm performs three tasks simultaneously: control of the robotic mechanism so that proper torch motion is achieved while minimizing the sum-of-squares of joint displacement; control of the torch while the part is maintained in a desirable orientation; and control of the wire feed mechanism location with respect to the moving welding torch. Also presented is a modification of this algorithm which permits it to be used for vertical-up welding. The details of this modification are discussed and simulation examples are provided for illustration and verification.

Automated GMA welding of austenitic stainless steel pipe

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tahash, G.J.

1996-12-31

The study focused on reducing weld cycle times of rotatable subassemblies (spools) using automated welding equipment. A unique automatic Gas Metal Arc Welding (GMAW) system was used to produce a series of pipe to pipe welds on 141 mm (5 in.) schedule 80 seamless stainless steel pipe. After manual tack welding, the adaptive control system welded the root pass of the argon gas backed open vee groove circumferential butt joints in the IG rotated position with short circuiting transfer GMAW. The fill and cover passes were welded automatically with spray transfer GMAW. Automatic welding cycle times were found to bemore » 50--80 percent shorter than the current techniques of roll welding with Shielded Metal Arc Welding and manual Gas Tungsten Arc Welding. Weld costs ({Brit_pounds}/m), including amortization, for the various systems were compared. The cost of automated GMA welds was virtually equivalent to the most competitive methods while depositing 75% more filler metal per year. Also investigated were metallurgical effects generated by weld thermal cycling, and the associated effects on mechanical properties of the weld joint. Mechanical properties of the welds met or exceeded those of the base metal. Sensitization of the pipe did not occur in the heat affected zone (HAZ), based on the absence of evidence of intergranular attack in modified Strauss corrosion tests and despite the fact of interpass temperatures well above recommended maximums. Cooling rates of 3--5 C/s in the heat affected zone of the four pass welds were measured by thermocouple technique and found to be within the non-sensitizing range for this alloy.« less

Arc brazing of austenitic stainless steel to similar and dissimilar metals

NASA Astrophysics Data System (ADS)

Moschini, Jamie Ian

There is a desire within both the stainless steel and automotive industries to introduce stainless steel into safety critical areas such as the crumple zone of modem cars as a replacement for low carbon mild steel. The two main reasons for this are stainless steel's corrosion resistance and its higher strength compared with mild steel. It has been anticipated that the easiest way to introduce stainless steel into the automotive industry would be to incorporate it into the existing design. The main obstacle to be overcome before this can take place is therefore how to join the stainless steel to the rest of the car body. In recent times arc brazil g has been suggested as a joining technique which will eliminate many of the problems associated with fusion welding of zinc coated mild steel to stainless steel.Similar and dissimilar parent material arc brazed joints were manufactured using three copper based filler materials and three shielding gases. The joints were tested in terms of tensile strength, impact toughness and fatigue properties. It was found that similar parent material stainless steel joints could be produced with a 0.2% proof stress in excess of the parent material and associated problems such as Liquid Metal Embrittlement were not experienced. Dissimilar parent material joints were manufactured with an ultimate tensile strength in excess of that of mild steel although during fatigue testing evidence of Liquid Metal Embrittlement was seen lowering the mean fatigue load.At the interface of the braze and stainless steel in the similar material butt joints manufactured using short circuit transfer, copper appeared to penetrate the grain boundaries of the stainless steel without embrittling the parent material. Further microscopic investigation of the interface showed that the penetration could be described by the model proposed by Mullins. However, when dissimilar metal butt joints were manufactured using spray arc transfer, penetration of copper into the stainless steel resulted in embrittlement as discussed by Glickman.

Characterization of a spray torch and analysis of process parameters

NASA Astrophysics Data System (ADS)

Ramasamy, R.; Selvarajan, V.

1999-07-01

Anode for a non-transferred DC plasma spray torch was designed to improve electrothermal efficiency. A theoretical calculation was made for the electrothermal efficiency in a DC plasma torch operating with argon at atmospheric pressure with power level in the range of 5.2 20 kW using energy balance equations. ANOVA for the two level factorial design was done. Plasma gas flow rate, current intensity, nozzle diameter and length were found to influence the efficiency. The efficiency was found to decrease with increase in current intensity and nozzle length and to increase with increase in nozzle diameter and gas flow rate. The overall energy balance calculations showed that the heat transfer to the plasma-forming gas decreases with increase in arc current and the same was more significant at higher flow rates. Plasma jet velocity for different flow rates, input to the torch and nozzle dimensions was calculated from the gas enthalpy. It was found that the velocity increased with increase in the power input to the torch and gas flow rate and decreased with increase in nozzle length and diameter. The current voltage characteristics of the torch operating with argon gas were studied for different gas flow rates. The Nottingham coefficients were calculated using least square method.

Bronchocarcinogenic properties of welding and thermal spraying fumes containing chromium in the rat.

PubMed

Berg, N O; Berlin, M; Bohgard, M; Rudell, B; Schütz, A; Warvinge, K

1987-01-01

The possible bronchocarcinogenic effects of fumes released during the shielded metal arc welding of stainless steel and the thermal spraying of chromium oxide (Cr2O3) have been studied on the rat. The fume particles were shown to contain tri- and hexavalent chromium in soluble and low soluble forms; they were collected and implanted as pellets in the bronchi of groups of 100 rats by the method of Laskin et al. A negative control group of 100 rats was included, as well as positive controls receiving pellets containing benz(a)pyrene. The experiment was continued for 34 months; no differences of biological significance were noted between the growth rates, survival times, and terminal organ weights of the test and negative control groups. At autopsy, the macroscopic and microscopic appearance of the organs in the three groups, including the local reaction to the implanted pellet, were similar. No precancerous changes were observed at the implantation sites; one rat, who received a pellet containing welding fumes, showed squamous cell carcinoma remote from the implantation site and not associated with the bronchus. It had the appearance of a metastasis. All three benz(a)pyrene control rats developed cancer at the implantation site. The occupational health implications of these findings are discussed.

Liquid Coatings for Reducing Corrosion of Steel in Concrete

NASA Technical Reports Server (NTRS)

MacDowell, Louis G.; Curran, Joseph

2003-01-01

Inorganic coating materials are being developed to slow or stop corrosion of reinforcing steel members inside concrete structures. It is much simpler and easier to use these coating materials than it is to use conventional corrosion-inhibiting systems based on impressed electric currents. Unlike impressed electrical corrosion-inhibiting systems, these coatings do not require continuous consumption of electrical power and maintenance of power-supply equipment. Whereas some conventional systems involve the use of expensive arc-spray equipment to apply the metallic zinc used as the sacrificial anode material, the developmental coatings can be applied by use of ordinary paint sprayers. A coating material of the type under development is formulated as a liquid containing blended metallic particles and/or moisture-attracting compounds. The liquid mixture is sprayed onto a concrete structure. Experiments have shown that even though such a coat resides on the exterior surface, it generates a protective galvanic current that flows to the interior reinforcing steel members. By effectively transferring the corrosion process from the steel reinforcement to the exterior coating, the protective current slows or stops corrosion of the embedded steel. Specific formulations have been found to meet depolarization criteria of the National Association of Corrosion Engineers (NACE) for complete protection of steel reinforcing bars ("rebar") embedded in concrete.

In situ stress relaxation mechanism of a superelastic NiTi shape memory alloy under hydrogen charging

NASA Astrophysics Data System (ADS)

Elkhal Letaief, Wissem; Hassine, Tarek; Gamaoun, Fehmi

2017-02-01

On account of its good biocompatibility, superelastic Ni-Ti arc wire alloys have been successfully used in orthodontic clinics. Nevertheless, delayed fracture in the oral cavity caused by hydrogen diffusion can be observed. The in situ stress relaxation susceptibility of a Ni-Ti shape memory alloy towards hydrogen embrittlement has been examined with respect to the current densities and imposed deformations. Orthodontic wires have been relaxed at different martensite volume fractions using current densities of 5, 10 and 20 A/m2 at 20 °C. The in situ relaxation stress shows that, for an imposed strain at the middle of the austenite-martensite transformation, the specimen fractures at the martensite-austenite reverse transformation. However, for an imposed strain at the beginning of the austenite-martensite plateau, the stress decreases in a similar way to the full austenite structure. Moreover, the stress plateau has been recorded at the reverse transformation for a short period. For the fully martensite structure, embrittlement occurs at a higher stress value. This behaviour is attributed to the interaction between the in situ austenite phase expansion and the diffusion of hydrogen in the different volume fractions of the martensite phase, produced at an imposed strain.

Using Electrostriction to Manipulate Ullage in Microgravity

NASA Technical Reports Server (NTRS)

Chui, Talso; Strayer, Donald

2006-01-01

A report proposes to use electrostriction to manipulate the ullage in a tank containing a dielectric liquid in a microgravitational environment. In the original intended application, the liquid would be a spacecraft propellant and the goal would be to force the ullage (comprising bubbles of noncondensible gas) to coalesce at one end of the tank, to enable use of one of the established means of (1) measuring the position of the gas/liquid interface and (2) inferring the quantity of liquid from the measurement. Electrically insulated wires would be installed in the tank, shaped and positioned so that application of a suitably high potential (e.g., 1 kV) between adjacent wires in successive pairs would give rise to a sufficient electric field gradient along the tank. The resulting electrostriction in the liquid would give rise to a pressure gradient that would force the ullage toward the low-electric-field-magnitude end of the tank. The feasibility of this proposal was demonstrated in an experiment in a tank containing liquid helium aboard an airplane flying a low-gravity arc. The ullage-segregating electrostrictive effect is expected to be considerably greater in other liquids.

Measurement of velocity distribution and turbulence in a special wind tunnel using a laser Doppler velocimeter

NASA Astrophysics Data System (ADS)

Mueller, J.; Petersen, J. C.; Pilz, E.; Wiegand, H.

1981-06-01

The flow behavior in a jet mixing visualization chamber for turbulent fuel spray mixing with air under compression, e.g., at top dead center in diesel engines, was investigated with a laser Doppler velocimeter. The measurements were performed in two cuts in the profile perpendicular to the flow direction. The range of flow conditions in the measuring chamber was tested. The measurements were conducted with and without turbulence grids and shear flow grids behind the inlet nozzle. Wire grids did not enhance the turbulence in the measuring chamber. One of the tested shear flow grids produced shear flow as expected. A turbulence grid whose design was based on experimental results, produced a turbulence degree of up to 30% over the whole measuring cross section.

Placement accuracy gauge for electrical components and method of using same

DOEpatents

Biggs, Peter M.; Dancer, Linda K.; Yerganian, Simon S.

1988-10-11

Surface mounted electrical components are typically assembled on printed wiring boards by automatic machines. It is important that the machines accurately move with respect to both X and Y rotational axes in order to insure that components are positioned precisely on connector pads of the printed wiring board being assembled. In accordance with the instant invention, a gauge is used to facilitate convenient accuracy checks. The gauge is a glass substrate on which grids of 0.005 inch lines are scribed to form location and orientation fields where components are to be placed. The grids are referenced from either fiducial marks or the edge of the substrate to establish known positions within the grids. The equipment to be evaluated is programmed to place components in known positions and the components are held in place by tacky adhesive that is sprayed on the substrate prior to placing the components. The accuracy of the component position is then compared to the programmed position by placing the substrate on a light table and observing the component location. If a significant inaccuracy with respect to any of the axes exists, the inaccuracy is apparent because the component is not aligned properly with the grid. If a precise measurement of an axis inaccuracy is desired, a measuring microscope may be utilized.

Placement accuracy gauge for electrical components and method of using same

DOEpatents

Biggs, P.M.; Dancer, L.K.; Yerganian, S.S.

1987-11-12

Surface mounted electrical components are typically assembled on printed wiring board by automatic machines. It is important that the machines accurately move with respect to both X and Y rotational axes in order to insure that components are positioned precisely on connector pads of the printed wiring board being assembled. In accordance with the instant invention, a gauge is used to facilitate convenient accuracy checks. The gauge is a glass substrate on which grids of 0.005 inch lines are scribed to form location and orientation fields where components are to be placed. The grids are referenced from ether fiducial marks or the edge of the substrate to establish known positions within the grids. The equipment to be evaluated is programmed to place components in known positions and the components are held in place by tacky adhesive that is sprayed on the substrate prior to placing the components. The accuracy of the component position is then compared to the programmed position by placing the substrate on a light table and observing the component location. If a significant inaccuracy with respect to any of the axes exists, the inaccuracy is apparent because the component is not aligned properly with the grid. If a precise measurement of an axis inaccuracy is desired, a measuring microscope may be utilized. 6 figs.

High-Temperature Extensometry and PdCr Temperature-Compensated Wire Resistance Strain Gages Compared

NASA Technical Reports Server (NTRS)

1996-01-01

A detailed experimental evaluation is underway at the NASA Lewis Research Center to compare and contrast the performance of the PdCr/Pt dual-element temperature-compensated wire resistance strain gage with that of conventional high-temperature extensometry. The advanced PdCr gage, developed by researchers at Lewis, exhibits desirable properties and a relatively small and repeatable apparent strain to 800 C. This gage represents a significant advance in technology because existing commercial resistance strain gages are not reliable for quasi-static strain measurements above approximately 400 C. Various thermal and mechanical loading spectra are being applied by a high-temperature thermomechanical uniaxial testing system to evaluate the two strain-measurement systems. This is being done not only to compare and contrast the two strain sensors, but also to investigate the applicability of the PdCr strain gage to the coupon-level specimen testing environment typically employed when the high-temperature mechanical behavior of structural materials is characterized. Strain measurement capabilities to 800 C are being investigated with a nickel-base superalloy, Inconel 100 (IN 100), substrate material and application to TMC's is being examined with the model system, SCS-6/Ti-15-3. Furthermore, two gage application techniques are being investigated in the comparison study: namely, flame-sprayed and spot welding.

Low-frequency RF Coupling To Unconventional (Fat Unbalanced) Dipoles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ong, M M; Brown, C G; Perkins, M P

2010-12-07

The report explains radio frequency (RF) coupling to unconventional dipole antennas. Normal dipoles have thin equal length arms that operate at maximum efficiency around resonance frequencies. In some applications like high-explosive (HE) safety analysis, structures similar to dipoles with ''fat'' unequal length arms must be evaluated for indirect-lightning effects. An example is shown where a metal drum-shaped container with HE forms one arm and the detonator cable acts as the other. Even if the HE is in a facility converted into a ''Faraday cage'', a lightning strike to the facility could still produce electric fields inside. The detonator cable concentratesmore » the electric field and carries the energy into the detonator, potentially creating a hazard. This electromagnetic (EM) field coupling of lightning energy is the indirect effect of a lightning strike. In practice, ''Faraday cages'' are formed by the rebar of the concrete facilities. The individual rebar rods in the roof, walls and floor are normally electrically connected because of the construction technique of using metal wire to tie the pieces together. There are two additional requirements for a good cage. (1) The roof-wall joint and the wall-floor joint must be electrically attached. (2) All metallic penetrations into the facility must also be electrically connected to the rebar. In this report, it is assumed that these conditions have been met, and there is no arcing in the facility structure. Many types of detonators have metal ''cups'' that contain the explosives and thin electrical initiating wires, called bridge wires mounted between two pins. The pins are connected to the detonator cable. The area of concern is between the pins supporting the bridge wire and the metal cup forming the outside of the detonator. Detonator cables usually have two wires, and in this example, both wires generated the same voltage at the detonator bridge wire. This is called the common-mode voltage. The explosive component inside a detonator is relatively sensitive, and any electrical arc is a concern. In a safety analysis, the pin-to-cup voltage, i.e., detonator voltage, must be calculated to decide if an arc will form. If the electric field is known, the voltage between any two points is simply the integral of the field along a line between the points. Eq. 1.1. For simplicity, it is assumed that the electric field and dipole elements are aligned. Calculating the induced detonator voltage is more complex because of the field concentration caused by metal components. If the detonator cup is not electrically connected to the metal HE container, the portion of the voltage generated by the dipole at the detonator will divide between the container-to-cup and cup-to-pin gaps. The gap voltages are determined by their capacitances. As a simplification, it will be assumed the cup is electrically attached, short circuited, to the HE container. The electrical field in the pin-to-cup area is determined by the field near the dipole, the length of the dipole, the shape of the arms, and the orientation of the arms. Given the characteristics of a lightning strike and the inductance of the facility, the electric fields in the ''Faraday cage'' can be calculated. The important parameters for determining the voltage in an empty facility are the inductance of the rebars and the rate of change of the current, Eq. 1.3. The internal electric fields are directly related to the facility voltages, however, the electric fields in the pin-to-cup space is much higher than the facility fields because the antenna will concentrate the fields covered by the arms. Because the lightning current rise-time is different for every strike, the maximum electric field and the induced detonator voltage should be described by probability distributions. For pedantic purposes, the peak field in the simulations will be simply set to 1 V/m. Lightning induced detonator voltages can be calculated by scaling up with the facility fields. Any metal object around the explosives, such as a work stand, will also distort the electric fields. A computer simulation of the electric fields in a facility with a work stand and HE container is shown. In this configuration, the work stand is grounded, and the intensity of field around the HE (denoted in dark blue) is reduced relative to the rest of the work bay (denoted lighter blue). The area above work stand posts has much higher fields indicated by red. The fields on top of the container are also affected. Without an understanding of how the electric fields are distributed near the detonator cable and container, it is not possible to calculate the induced detonator voltage. The average lightning current has rise- and fall-times of 3 us and 50 us respectively, and this translates to a wavelength that is long when compared with the length of the HE container or detonator cable.« less

Latest MIG, TIG arc-YAG laser hybrid welding systems for various welding products

NASA Astrophysics Data System (ADS)

Ishide, Takashi; Tsubota, Shuho; Watanabe, Masao

2003-03-01

Laser welding is capable of high-efficiency low-strain welding, and so its applications are started to various products. We have also put the high-power YAG laser of up to 10 kW to practical welding use for various products. On the other hand the weakest point of this laser welding is considered to be strict in the welding gap aiming allowance. In order to solve this problem, we have developed hybrid welding of TIG, MIG arc and YAG laser, taking the most advantages of both the laser and arc welding. Since the electrode is coaxial to the optical axis of the YAG laser in this process, it can be applied to welding of various objects. In the coaxial MIG, TIG-YAG welding, in order to make irradiation positions of the YAG laser beams having been guided in a wire or an electrode focused to the same position, the beam transmitted in fibers is separated to form a space between the separated beams, in which the laser is guided. With this method the beam-irradiating area can be brought near or to the arc-generating point. This enables welding of all directions even for the member of a three-dimensional shape. This time we carried out welding for various materials and have made their welding of up to 1 mm or more in welding groove gap possible. We have realized high-speed 1-pass butt welding of 4m/min in welding speed with the laser power of 3 kW for an aluminum alloy plate of approximately 4 mm thick. For a mild steel plate also we have realized butt welding of 1m/min with 5 kW for 6 mm thick. Further, in welding of stainless steel we have shown its welding possibility, by stabilizing the arc with the YAG laser in the welding atmosphere of pure argon, and shown that this welding is effective in high-efficiency welding of various materials. Here we will report the fundamental welding performances and applications to various objects for the coaxial MIG, TIG-YAG welding we have developed.

Synthesis of SiO(x) powder using DC arc plasma.

PubMed

Jung, Chan-Ok; Park, Dong-Wha

2013-02-01

SiO(x) was prepared by DC arc plasma and applied to the anode material of lithium ion batteries. A pellet of a mixture of Si and SiO2 was used as the raw material. The ratios of the silicon and silicon dioxide (SiO2) mixtures were varied by controlling the Si-SiO2 molar ratio (Si-SiO2 = 1-4). Hydrogen gas was used as the reduction atmosphere in the chamber. The prepared SiO(x) was collected on the chamber wall. The obtained SiO(x) was characterized by X-ray diffraction (XRD), field emission-scanning electron microscopy (FE-SEM), energy dispersive spectroscopy (EDS), transmission electron microscopy (TEM) and X-ray photoelectron spectroscopy (XPS). XRD and TEM showed that the phase composition of the prepared particles was composed of amorphous SiO(x) and crystalline Si. The prepared SiO(x) showed wire and spherical morphology. XPS indicated the bonding state and 'x' value of the prepared SiO(x), which was close to one. The result of prepared SiO(x) is discussed from thermodynamic equilibrium calculations. The electrochemical behavior of the silicon monoxide anode was investigated.

Effect of Manufacturing Process on the Biocompatibility and Mechanical Properties of Ti-30Ta Alloy

NASA Astrophysics Data System (ADS)

Gill, P.; Munroe, N.; Pulletikurthi, C.; Pandya, S.; Haider, W.

2011-07-01

Ti alloys have been widely used in the aerospace, chemical, and biomedical industries for their high strength/weight ratio and corrosion resistance. However, Nitinol's usage in the latter industry has been fraught with concerns of allergic and toxic effects of Ni released from implants. Recently, much attention has been placed on the development of Ni-free Ti-Ta alloys, which are considered prime candidates for applications such as metal-on-metal spinal disk replacements, orthopedic implants, cardiovascular stents, dental posts, and guide wires. In this research, the biocompatibility of Ti-30Ta alloys manufactured by powder metallurgy (PM) and arc melting (ARC) were investigated. The corrosion resistance of each alloy was determined in accordance with ASTM F 2129-08 in phosphate buffered saline (PBS) and PBS with amino acids at 37 °C. The concentration of metal ions released during corrosion was measured by Inductively Coupled Plasma Mass Spectroscopy (ICP-MS). Scanning Electron Microscopy (SEM) was used to assess the morphology of the alloys before and after corrosion. Vicker's hardness tests were performed to compare the hardness and tensile strength of the alloys. Human osteoblast cells were successfully grown on the surface of both alloys.

Optimization of cladding parameters for resisting corrosion on low carbon steels using simulated annealing algorithm

NASA Astrophysics Data System (ADS)

Balan, A. V.; Shivasankaran, N.; Magibalan, S.

2018-04-01

Low carbon steels used in chemical industries are frequently affected by corrosion. Cladding is a surfacing process used for depositing a thick layer of filler metal in a highly corrosive materials to achieve corrosion resistance. Flux cored arc welding (FCAW) is preferred in cladding process due to its augmented efficiency and higher deposition rate. In this cladding process, the effect of corrosion can be minimized by controlling the output responses such as minimizing dilution, penetration and maximizing bead width, reinforcement and ferrite number. This paper deals with the multi-objective optimization of flux cored arc welding responses by controlling the process parameters such as wire feed rate, welding speed, Nozzle to plate distance, welding gun angle for super duplex stainless steel material using simulated annealing technique. Regression equation has been developed and validated using ANOVA technique. The multi-objective optimization of weld bead parameters was carried out using simulated annealing to obtain optimum bead geometry for reducing corrosion. The potentiodynamic polarization test reveals the balanced formation of fine particles of ferrite and autenite content with desensitized nature of the microstructure in the optimized clad bead.

Fabrication of graphene/titanium carbide nanorod arrays for chemical sensor application.

PubMed

Fu, Chong; Li, Mingji; Li, Hongji; Li, Cuiping; Qu, Changqing; Yang, Baohe

2017-03-01

Vertically stacked graphene nanosheet/titanium carbide nanorod array/titanium (graphene/TiC nanorod array) wires were fabricated using a direct current arc plasma jet chemical vapor deposition (DC arc plasma jet CVD) method. The graphene/TiC nanorod arrays were characterized by scanning electron microscopy, transmission electron microscopy, Raman spectroscopy, X-ray photoelectron spectroscopy, and X-ray diffraction spectroscopy. The TiO 2 nanotube array was reduced to the TiC nanorod array, and using those TiC nanorods as nucleation sites, the vertical graphene layer was formed on the TiC nanorod surface. The multi-target response mechanisms of the graphene/TiC nanorod array were investigated for ascorbic acid (AA), dopamine (DA), uric acid (UA), and hydrochlorothiazide (HCTZ). The vertically stacked graphene sheets facilitated the electron transfer and reactant transport with a unique porous surface, high surface area, and high electron transport network of CVD graphene sheets. The TiC nanorod array facilitated the electron transfer and firmly held the graphene layer. Thus, the graphene/TiC nanorod arrays could simultaneously respond to trace biomarkers and antihypertensive drugs. Copyright © 2016 Elsevier B.V. All rights reserved.

Pipeline welding goes mechanized

DOE Office of Scientific and Technical Information (OSTI.GOV)

Beeson, R.

1999-11-01

Spread four has bugs in the cornfield--but not to worry. The bug referred to here is a mechanized welding bug, specifically a single welding head, computer-aided gas metal arc (GMAW) system from CRC-Evans Automatic Welding powered by a Miller Electric XMT{reg{underscore}sign} 304 inverter-based welding machine. The bug operator and owner of 32 inverters is Welded Construction, L.P., of Perrysburgh, Ohio. Spread four is a 147-mile stretch of the Alliance Pipeline system (Alliance) cutting through the cornfields of northeast Iowa. While used successfully in Canada and Europe for onshore and offshore pipeline construction for 30 years, this is the first large-scalemore » use of mechanized welding in the US on a cross-country pipeline. On longer, larger-diameter and thicker-wall pipe projects--the Alliance mainline has 1,844 miles of pipe, most of it 36-in. diameter with a 0.622-in. wall thickness--mechanized GMAW offers better productivity than manual shielded metal arc welding (SMAW). In addition, high-strength steels, such as the API 5L Grade X70 pipe used on the Alliance, benefit from the low-hydrogen content of certain solid and tubular wire electrodes.« less

Theory of flux cutting and flux transport at the critical current of a type-II superconducting cylindrical wire

DOE Office of Scientific and Technical Information (OSTI.GOV)

Clem, John R

2011-02-17

I introduce a critical-state theory incorporating both flux cutting and flux transport to calculate the magnetic-field and current-density distributions inside a type-II superconducting cylinder at its critical current in a longitudinal applied magnetic field. The theory is an extension of the elliptic critical-state model introduced by Romero-Salazar and Pérez-Rodríguez. The vortex dynamics depend in detail on two nonlinear effective resistivities for flux cutting (ρ{sub ∥}) and flux flow (ρ{sub ⊥}), and their ratio r=ρ{sub ∥}/ρ{sub ⊥}. When r<1, the low relative efficiency of flux cutting in reducing the magnitude of the internal magnetic-flux density leads to a paramagnetic longitudinal magneticmore » moment. As a model for understanding the experimentally observed interrelationship between the critical currents for flux cutting and depinning, I calculate the forces on a helical vortex arc stretched between two pinning centers when the vortex is subjected to a current density of arbitrary angle Φ. Simultaneous initiation of flux cutting and flux transport occurs at the critical current density J{sub c}(Φ) that makes the vortex arc unstable.« less

Theory of flux cutting and flux transport at the critical current of a type-II superconducting cylindrical wire

DOE Office of Scientific and Technical Information (OSTI.GOV)

Clem, John R.

2011-02-17

I introduce a critical-state theory incorporating both flux cutting and flux transport to calculate the magnetic-field and current-density distributions inside a type-II superconducting cylinder at its critical current in a longitudinal applied magnetic field. The theory is an extension of the elliptic critical-state model introduced by Romero-Salazar and Perez-Rodriguez. The vortex dynamics depend in detail on two nonlinear effective resistivities for flux cutting ({rho}{parallel}) and flux flow ({rho}{perpendicular}), and their ratio r = {rho}{parallel}/{rho}{perpendicular}. When r < 1, the low relative efficiency of flux cutting in reducing the magnitude of the internal magnetic-flux density leads to a paramagnetic longitudinal magneticmore » moment. As a model for understanding the experimentally observed interrelationship between the critical currents for flux cutting and depinning, I calculate the forces on a helical vortex arc stretched between two pinning centers when the vortex is subjected to a current density of arbitrary angle {phi}. Simultaneous initiation of flux cutting and flux transport occurs at the critical current density J{sub c}({phi}) that makes the vortex arc unstable.« less

Theory of flux cutting and flux transport at the critical current of a type-II superconducting cylindrical wire

NASA Astrophysics Data System (ADS)

Clem, John R.

2011-06-01

I introduce a critical-state theory incorporating both flux cutting and flux transport to calculate the magnetic-field and current-density distributions inside a type-II superconducting cylinder at its critical current in a longitudinal applied magnetic field. The theory is an extension of the elliptic critical-state model introduced by Romero-Salazar and Pérez-Rodríguez. The vortex dynamics depend in detail on two nonlinear effective resistivities for flux cutting (ρ∥) and flux flow (ρ⊥), and their ratio r=ρ∥/ρ⊥. When r<1, the low relative efficiency of flux cutting in reducing the magnitude of the internal magnetic-flux density leads to a paramagnetic longitudinal magnetic moment. As a model for understanding the experimentally observed interrelationship between the critical currents for flux cutting and depinning, I calculate the forces on a helical vortex arc stretched between two pinning centers when the vortex is subjected to a current density of arbitrary angle ϕ. Simultaneous initiation of flux cutting and flux transport occurs at the critical current density Jc(ϕ) that makes the vortex arc unstable.

Combustion of LOX with H2(sub g) under subcritical, critical, and supercritical conditions and experimental observation of dense spray and mixing of impinging jets

NASA Technical Reports Server (NTRS)

Kuo, Kenneth K.; Hsieh, W. H.; Yang, A. S.; Brown, J. J.; Cheung, F. B.; Woodward, R. D.; Kline, M. C.

1992-01-01

Progress made during the period of February 1 to October 15, 1992 is reported. The overall objective of Task 1 of the investigation is to achieve a better understanding of the combustion processes of liquid oxygen and gaseous hydrogen under subcritical, critical, and supercritical conditions. Specific objectives of the research program are: (1) to determine the evaporation- and burning-rate characteristics of LOX in hydrogen/helium environments under broad ranges of operating conditions; (2) to measure species concentration profile and surface temperature of LOX employing the gas chromatography and fine-wire thermocouples under non-reacting flow situations; (3) to perform a fugacity-based multicomponent thermodynamic phase equilibrium analysis for examining the high-pressure vapor-liquid equilibrium behavior at the liquid surface of LOX; (4) to formulate and solve a theoretical model for simulating the evaporation and combustion processes in a LOX/H2/He system; and (5) to validate the theoretical model with the measured experimental data. Task 2 of the investigation is described. Observation of a like-on-like injector element in the near-injector region performed in the previous phase of this project has identified the existence of a high Reynolds number regime in which the pre-impingement jets are fully turbulent and undergoing surface breakup. The new spray regime, which has not been observed by previous investigators, is characterized by the presence of many fine droplets and the disappearance of the well-defined liquid breakup wave pattern in the post-impingement region. It is speculated that a cavitating region may be present within the orifice so that it could induce strong turbulence, leading to an onset of atomization of the jets prior to impingement. To further investigate the dense spray behavior of the impinging jets in the high Reynolds number region, experiments were conducted using Plexiglas injector components for direct internal flow observation. The main objective is to determine under what conditions a cavitating region would form and whether or not the cavitation is reponsible for the development of the high Reynolds number spray regime. The procedure and major findings of the injector cavitation study are described.

SU-E-T-633: Preparation and Planning of a VMAT Multi - Arc Radiation Therapy Technique for Full Scalp Treatment

DOE Office of Scientific and Technical Information (OSTI.GOV)

Araujo, C; Bardock, A; Berkelaar, S

2015-06-15

Purpose: The target volume for angiosarcoma of the scalp encompasses the entire scalp. Full scalp radiotherapy (FSRT) requires careful design of required bolus, immobilization and marking of the field before the patient CT is acquired. A VMAT multi-arc technique was designed to deliver FSRT for a patient with angiosarcoma of the scalp to a dose of 6000cGy in 25 fractions. Methods: A custom bolus helmet was fabricated from a 0.5 cm thick sheet of aquaplast material, which was molded to the patient’s head. With the bolus helmet in place the patient was then positioned supine on a H&N immobilization board.more » A custom vaclock bag positioned on a standard headrest and a thermoplastic mask were used to immobilize the patient. Additional bolus to cover the remaining treatment area was attached to the mask. We acquired two CT scans of the patient’s head, one in treatment position and an additional scan without the immobilization mask with wires marking the treatment area that the oncologist had delineated on the patient’s skin. The second scan was registered to the first and used to define the treatment CTV. A four-arc VMAT treatment planned using Varian-Eclipse was optimized to cover the skin with a PTV margin while sparing the brain and limiting the dose to the optic apparatus and lacrimal glands. Daily treatment setup was verified using anterior and lateral kV on-board-imaging. To verify the treated dose, TLDs were positioned on the patient’s scalp during one fraction. Results: With full dose coverage to the PTV, the mean dose to the brain was less than 24 Gy. The dose measured by the TLDs (mean difference 1%, standard deviation 4%)showed excellent agreement with the treatment planning calculation. Conclusion: FSRT delivered with a bolus helmet and a VMAT multi-arc technique can be accurately delivered with high dose uniformity and conformality.« less

Plasma Interactions With a Negative Biased Electrodynamic Tether

NASA Technical Reports Server (NTRS)

Vaughn, Jason A.; Curtis, Leslie; Welzyn, Ken J.

2004-01-01

The ProSEDS conductive tether design incorporates two distinct types of tethers from a plasma interaction viewpoint. The 200 m closest to the Delta II spacecraft is insulated from the plasma, and the remaining 4800 m is semi-bare. This latter portion is considered semi-bare because a conductive coating, which is designed to collect electrons from the plasma, was applied to the wires to regulate the overall tether temperature. Because the tether has both insulating and conductive tether sections, a transition point exists between the two that forms a triple point with the space plasma. Also, insulated tethers can arc to the space plasma if the insulation is weakened or breached by pinholes caused by either improper handling or small meteoroid and orbital debris strikes. Because electrodynamic tethers are typically long, they have a high probability of these impacts. The particles, which strike the tether, may not have sufficient size to severe the tether, but they can easily penetrate the tether insulation producing a plasma discharge to the ambient plasma. Samples of both the ProSEDS tether transition region and the insulated tether section with various size of pinholes were placed into the MSFC plasma chamber and biased to typical ProSEDS open circuit tether potentials (-500 V to -1600 V). The results of the testing showed that the transition region of the tether (i.e. the triple point) arced to the ambient plasma at -900 V, and the tethers damaged by a pinhole or simulated debris strike arced to the plasma between -700 V and -900 V. Specific design steps were taken to eliminate the triple point issue in the ProSEDS tether design and make it ready for flight. To reduce the pinhole arcing risk, ProSEDS mission operations were changed to eliminate the high negative potential on the insulated tether. The results of the testing campaign and the design changes implemented to ensure a successful flight are described.

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

NASA Technical Reports Server (NTRS)

Wright, Kenneth H., Jr.; Schneider, Todd A.; Vaughn, Jason A.; Hoang, Bao; Wong, Frankie

2015-01-01

A test was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by SSL. The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge testing at two string voltages (100 V, 150 V) and four array current (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micros to 2.9 ms. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission application.

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

NASA Technical Reports Server (NTRS)

Wright, K. H.; Schneider, T. A.; Vaughn, J. A.; Hoang, B.; Wong, F.

2014-01-01

A test was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by SSL. The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge testing at two string voltages (100 V, 150 V) and four array current (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 µs to 2.9 ms. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission application.

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

NASA Technical Reports Server (NTRS)

Wright, Kenneth H., Jr.; Schneider, Todd A.; Vaughn, Jason A.; Hoang, Bao; Wong, Frankie

2014-01-01

Testing was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by Space Systems/Loral, LLC (SSL). The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge (ESD) testing at two string voltages (100 V, 150 V) and four array currents (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micro-seconds to 2.75 milli-seconds. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission.

An experimental and computational investigation of the flow field about a transonic airfoil in supercritical flow with turbulent boundary-layer separation

NASA Technical Reports Server (NTRS)

Rubesin, M. W.; Okuno, A. F.; Levy, L. L., Jr.; Mcdevitt, J. B.; Seegmiller, H. L.

1976-01-01

A combined experimental and computational research program is described for testing and guiding turbulence modeling within regions of separation induced by shock waves incident in turbulent boundary layers. Specifically, studies are made of the separated flow the rear portion of an 18%-thick circular-arc airfoil at zero angle of attack in high Reynolds number supercritical flow. The measurements include distributions of surface static pressure and local skin friction. The instruments employed include highfrequency response pressure cells and a large array of surface hot-wire skin-friction gages. Computations at the experimental flow conditions are made using time-dependent solutions of ensemble-averaged Navier-Stokes equations, plus additional equations for the turbulence modeling.

Deep Charging Evaluation of Satellite Power and Communication System Components

NASA Technical Reports Server (NTRS)

Schneider, T. A.; Vaughn, J. A.; Chu, B.; Wong, F.; Gardiner, G.; Wright, K. H.; Phillips, B.

2016-01-01

A set of deep charging tests has been carried out by NASA's Marshall Space Flight Center on subscale flight-like samples developed by Space Systems/Loral, LLC. The samples, which included solar array wire coupons, a photovoltaic cell coupon, and a coaxial microwave transmission cable, were placed in passive and active (powered) circuit configurations and exposed to electron radiation. The energy of the electron radiation was chosen to deeply penetrate insulating (dielectric) materials on each sample. Each circuit configuration was monitored to determine if potentially damaging electrostatic discharge events (arcs) were developed on the coupon as a result of deep charging. The motivation for the test, along with charging levels, experimental setup, sample details, and results will be discussed.

Field deployable processing methods for stay-in-place ultrasonic transducers

NASA Astrophysics Data System (ADS)

Malarich, Nathan; Lissenden, Cliff J.; Tittmann, Bernhard R.

2018-04-01

Condition monitoring provides key data for managing the operation and maintenance of mechanical equipment in the power generation, chemical processing, and manufacturing industries. Ultrasonic transducers provide active monitoring capabilities by wall thickness measurements, elastic property determination, crack detection, and other means. In many cases the components operate in harsh environments that may include high temperature, radiation, and hazardous chemicals. Thus, it is desirable to have permanently affixed ultrasonic transducers for condition monitoring in harsh environments. Spray-on transducers provide direct coupling between the active element and the substrate, and can be applied to curved surfaces. We describe a deposition methodology for ultrasonic transducers that can be applied in the field. First, piezoceramic powders mixed into a sol-gel are air-spray deposited onto the substrate. Powder constituents are selected based on the service environment in which the condition monitoring will be performed. Then the deposited coating is pyrolyzed and partially densified using an induction heating system with a custom work coil designed to match the substrate geometry. The next step, applying the electrodes, is more challenging than might be expected because of the porosity of the piezoelectric coating and the potential reactivity of elements in the adjacent layers. After connecting lead wires to the electrodes the transducer is poled and a protective coating can be applied prior to use. Processing of a PZT-bismuth titanate transducer on a large steel substrate is described along with alternate methods.

Development of Thin Film Thermocouples on Ceramic Materials for Advanced Propulsion System Applications

NASA Technical Reports Server (NTRS)

Holanda, R.

1992-01-01

Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 c. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperature of 1500 C depending on the stability of the particular ceramic substrate.

Thin film thermocouples for high temperature measurement on ceramic materials

NASA Technical Reports Server (NTRS)

Holanda, Raymond

1992-01-01

Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high-heating-rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

Development of thin film thermocouples on ceramic materials for advanced propulsion system applications

NASA Technical Reports Server (NTRS)

Holanda, Raymond

1993-01-01

Thin film thermocouples were developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hr or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

Influences of Cr/Ni equivalent ratios of filler wires on pitting corrosion and ductility-dip cracking of AISI 316L weld metals

NASA Astrophysics Data System (ADS)

Kim, Y. H.; Kim, D. G.; Sung, J. H.; Kim, I. S.; Ko, D. E.; Kang, N. H.; Hong, H. U.; Park, J. H.; Lee, H. W.

2011-02-01

To study the pitting corrosion of AISI 316L weld metals according to the chromium/nickel equivalent ratio (Creq/Nieq ratio), three filler wires were newly designed for the flux-cored arc welding process. The weld metal with delta-ferrite at less than 3 vol.%, was observed for ductility-dip cracking (DDC) in the reheated region after multi-pass welding. The tensile strength and yield strength increased with increasing Creq/Nieq ratio. The result of anodic polarization tests in a 0.1 M NaCl solution at the room temperature (25) for 45 min, revealed that the base metal and weld metals have a similar corrosion potential of -0.34 VSCE. The weld metal with the highest content of Cr had the highest pitting potential (0.39 VSCE) and the passivation range (0.64 VSCE) was higher than the base metal (0.21 VSCE and 0.46 VSCE, respectively). Adding 0.001 M Na2S to the 0.1M NaCl solution, the corrosion occurred more severely by H2S. The corrosion potentials of the base metal and three weld metals decreased to -1.0 VSCE. DDC caused the decrease of the pitting potential by inducing a locally intense corrosion attack around the crack openings.

Plasma spraying method for forming diamond and diamond-like coatings

DOEpatents

Holcombe, C.E.; Seals, R.D.; Price, R.E.

1997-06-03

A method and composition is disclosed for the deposition of a thick layer of diamond or diamond-like material. The method includes high temperature processing wherein a selected composition including at least glassy carbon is heated in a direct current plasma arc device to a selected temperature above the softening point, in an inert atmosphere, and is propelled to quickly quenched on a selected substrate. The softened or molten composition crystallizes on the substrate to form a thick deposition layer comprising at least a diamond or diamond-like material. The selected composition includes at least glassy carbon as a primary constituent and may include at least one secondary constituent. Preferably, the secondary constituents are selected from the group consisting of at least diamond powder, boron carbide (B{sub 4}C) powder and mixtures thereof. 9 figs.

Upgraded HFIR Fuel Element Welding System

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sease, John D

2010-02-01

The welding of aluminum-clad fuel plates into aluminum alloy 6061 side plate tubing is a unique design feature of the High Flux Isotope Reactor (HFIR) fuel assemblies as 101 full-penetration circumferential gas metal arc welds (GMAW) are required in the fabrication of each assembly. In a HFIR fuel assembly, 540 aluminum-clad fuel plates are assembled into two nested annular fuel elements 610 mm (24-inches) long. The welding process for the HFIR fuel elements was developed in the early 1960 s and about 450 HFIR fuel assemblies have been successfully welded using the GMAW process qualified in the 1960 s. Inmore » recent years because of the degradation of the electronic and mechanical components in the old HFIR welding system, reportable defects in plate attachment or adapter welds have been present in almost all completed fuel assemblies. In October 2008, a contract was awarded to AMET, Inc., of Rexburg, Idaho, to replace the old welding equipment with standard commercially available welding components to the maximum extent possible while maintaining the qualified HFIR welding process. The upgraded HFIR welding system represents a major improvement in the welding system used in welding HFIR fuel elements for the previous 40 years. In this upgrade, the new inner GMAW torch is a significant advancement over the original inner GMAW torch previously used. The innovative breakthrough in the new inner welding torch design is the way the direction of the cast in the 0.762 mm (0.030-inch) diameter aluminum weld wire is changed so that the weld wire emerging from the contact tip is straight in the plane perpendicular to the welding direction without creating any significant drag resistance in the feeding of the weld wire.« less

Influence of nitrogen in the shielding gas on corrosion resistance of duplex stainless steel welds

NASA Astrophysics Data System (ADS)

Bhatt, R. B.; Kamat, H. S.; Ghosal, S. K.; de, P. K.

1999-10-01

The influence of nitrogen in shielding gas on the corrosion resistance of welds of a duplex stainless steel (grade U-50), obtained by gas tungsten arc (GTA) with filler wire, autogenous GTA (bead-on-plate), electron beam welding (EBW), and microplasma techniques, has been evaluated in chloride solutions at 30 °C. Pitting attack has been observed in GTA, electron beam welding, and microplasma welds when welding has been carried out using pure argon as the shielding gas. Gas tungsten arc welding with 5 to 10% nitrogen and 90 to 95% argon, as the shielding gas, has been found to result in an improved pitting corrosion resistance of the weldments of this steel. However, the resistance to pitting of autogenous welds (bead-on-plate) obtained in pure argon as the shielding gas has been observed to remain unaffected. Microscopic examination, electron probe microanalysis (EPMA), and x-ray diffraction studies have revealed that the presence of nitrogen in the shielding gas in the GTA welds not only modifies the microstructure and the austenite to ferrite ratio but also results in a nearly uniform distribution of the various alloying elements, for example, chromium, nickel, and molybdenum among the constitutent phases, which are responsible for improved resistance to pitting corrosion.

Mathematical modelling of convective processes in a weld pool under electric arc surfacing

NASA Astrophysics Data System (ADS)

Sarychev, V. D.; Granovskii, A. Yu; Nevskii, S. A.; Konovalov, S. V.

2017-01-01

The authors develop the mathematical model of convective processes in a molten pool under electric arc surfacing with flux-cored wire. The model is based on the ideas of how convective flows appear due to temperature gradient and action of electromagnetic forces. Influence of alloying elements in the molten metal was modeled as a non-linear dependence of surface tension upon temperature. Surface tension and its temperature coefficient were calculated according to the electron density functional method with consideration to asymmetric electron distribution at the interface “molten metal / shielding gas”. Simultaneous solution of Navier-Stokes and Maxwell equations according to finite elements method with consideration to the moving heat source at the interface showed that there is a multi-vortex structure in the molten metal. This structure gives rise to a downward heat flux which, at the stage of heating, moves from the centre of the pool and stirs it full width. At the cooling stage this flux moves towards the centre of the pool and a single vortex is formed near the symmetry centre. This flux penetration is ∼ 10 mm. Formation of the downward heat flux is determined by sign reversal of the temperature coefficient of surface tension due to the presence of alloying elements.

A high-performance nonenzymatic glucose sensor made of CuO-SWCNT nanocomposites.

PubMed

Quoc Dung, Nguyen; Patil, Dewyani; Jung, Hyuck; Kim, Dojin

2013-04-15

Nanocomposites of CuO and single-wall carbon nanotubes (SWCNTs) were synthesized using an arc-discharging graphite rod that contained copper wires. Simultaneous arc discharges produced a CuO-SWCNT composite network. The crystalline structure and morphology of the CuO-SWCNT composite films were investigated using XRD, Raman spectroscopy, FE-SEM and TEM. The electrochemical properties were investigated by cyclic voltammogram and amperometric measurements in a 0.1 M NaOH solution. The CuO content in the CuO-SWCNT nanocomposites was optimized for nonenzymatic glucose detection. The glucose sensing properties of the optimized CuO-SWCNT electrode showed good stability, selectivity, and linear glucose detection that ranged from 0.05 to 1800 μM with a higher sensitivity of 1610 μA cm⁻² mM⁻¹, a quick response time of 1-2 s, and the lowest limit of detection at 50 nM. The sensing performance was better than the pure CuO and SWCNT sensors, and the synergetic effect of the composite sensor was attributed to the high conductivity network of highly porous nanowires. The sensor also showed a good response in a human serum sample, which proves its high potential towards a commercial nonenzymatic glucose sensor. Copyright © 2012 Elsevier B.V. All rights reserved.

Influence of nitrogen in the shielding gas on corrosion resistance of duplex stainless steel welds

DOE Office of Scientific and Technical Information (OSTI.GOV)

Bhatt, R.B.; Kamat, H.S.; Ghosal, S.K.

1999-10-01

The influence of nitrogen in shielding gas on the corrosion resistance of welds of a duplex stainless steel (grade U-50), obtained by gas tungsten arc (GTA) with filler wire, autogenous GTA (bead-on-plate), electron beam welding (EBW), and microplasma techniques, has been evaluated in chloride solutions at 30 C. Pitting attack has been observed in GTA, electron beam welding, and microplasma welds when welding has been carried out using pure argon as the shielding gas. Gas tungsten arc welding with 5 to 10% nitrogen and 90 to 95% argon, as the shielding gas, has been found to result in an improvedmore » pitting corrosion resistance of the weldments of this steel. However, the resistance of pitting of autogenous welds (bead-on-plate) obtained in pure argon as the shielding gas has been observed to remain unaffected. Microscopic examination, electron probe microanalysis (EPMA), and x-ray diffraction studies have revealed that the presence of nitrogen in the shielding gas in the GTA welds not only modifies the microstructure and the austenite to ferrite ratio but also results in a nearly uniform distribution of the various alloying elements, for example, chromium, nickel, and molybdenum among the constituent phases, which are responsible for improved resistance to pitting corrosion.« less

A study of internal structure in components made by additive manufacturing process using 3 D X-ray tomography

DOE Office of Scientific and Technical Information (OSTI.GOV)

Raguvarun, K., E-mail: prajagopal@iitm.ac.in; Balasubramaniam, Krishnan, E-mail: prajagopal@iitm.ac.in; Rajagopal, Prabhu, E-mail: prajagopal@iitm.ac.in

Additive manufacturing methods are gaining increasing popularity for rapidly and efficiently manufacturing parts and components in the industrial context, as well as for domestic applications. However, except when used for prototyping or rapid visualization of components, industries are concerned with the load carrying capacity and strength achievable by additive manufactured parts. In this paper, the wire-arc additive manufacturing (AM) process based on gas tungsten arc welding (GTAW) has been examined for the internal structure and constitution of components generated by the process. High-resolution 3D X-ray tomography is used to gain cut-views through wedge-shaped parts created using this GTAW additive manufacturingmore » process with titanium alloy materials. In this work, two different control conditions for the GTAW process are considered. The studies reveal clusters of porosities, located in periodic spatial intervals along the sample cross-section. Such internal defects can have a detrimental effect on the strength of the resulting AM components, as shown in destructive testing studies. Closer examination of this phenomenon shows that defect clusters are preferentially located at GTAW traversal path intervals. These results highlight the strong need for enhanced control of process parameters in ensuring components with minimal defects and higher strength.« less

A study of internal structure in components made by additive manufacturing process using 3 D X-ray tomography

NASA Astrophysics Data System (ADS)

Raguvarun, K.; Balasubramaniam, Krishnan; Rajagopal, Prabhu; Palanisamy, Suresh; Nagarajah, Romesh; Hoye, Nicholas; Curiri, Dominic; Kapoor, Ajay

2015-03-01

Additive manufacturing methods are gaining increasing popularity for rapidly and efficiently manufacturing parts and components in the industrial context, as well as for domestic applications. However, except when used for prototyping or rapid visualization of components, industries are concerned with the load carrying capacity and strength achievable by additive manufactured parts. In this paper, the wire-arc additive manufacturing (AM) process based on gas tungsten arc welding (GTAW) has been examined for the internal structure and constitution of components generated by the process. High-resolution 3D X-ray tomography is used to gain cut-views through wedge-shaped parts created using this GTAW additive manufacturing process with titanium alloy materials. In this work, two different control conditions for the GTAW process are considered. The studies reveal clusters of porosities, located in periodic spatial intervals along the sample cross-section. Such internal defects can have a detrimental effect on the strength of the resulting AM components, as shown in destructive testing studies. Closer examination of this phenomenon shows that defect clusters are preferentially located at GTAW traversal path intervals. These results highlight the strong need for enhanced control of process parameters in ensuring components with minimal defects and higher strength.

Universite de Nancy (France) measurement report

NASA Astrophysics Data System (ADS)

Hadni, A.; Gerbaux, X.

1991-10-01

Measurements made by conventional Fourier transform spectroscopy using a polarizing wire grid interferometer with roof top reflectors and a rotating polarizing radiation chopper giving 10 Hz radiation modulation are presented. The radiation source used is a mercury vapor arc discharge lamp, and the detector a pumped liquid helium temperature silicon bolometer with a teflon input window and a low temperature quartz wedge acting as a low pass filter. The power transmission spectrum of each specimen measured is determined at nearly normal incidence with the specimen placed in a nominally collimated beam between the final analyzer grid and the output lens. The interferograms are recorded over a range of moving mirror positions about the position of zero path difference. No interferogram weighting function is used in the measurements. The spectral resolution of the measurements is 0.006 cm.

Additive Manufacturing of Shape Memory Alloys

NASA Astrophysics Data System (ADS)

Van Humbeeck, Jan

2018-04-01

Selective Laser Melting (SLM) is an additive manufacturing production process, also called 3D printing, in which functional, complex parts are produced by selectively melting patterns in consecutive layers of powder with a laser beam. The pattern the laser beam is following is controlled by software that calculates the pattern by slicing a 3D CAD model of the part to be constructed. Apart from SLM, also other additive manufacturing techniques such as EBM (Electron Beam Melting), FDM (Fused Deposition Modelling), WAAM (Wire Arc Additive Manufacturing), LENS (Laser Engineered Net Shaping such as Laser Cladding) and binder jetting allow to construct complete parts layer upon layer. But since more experience of AM of shape memory alloys is collected by SLM, this paper will overview the potentials, limits and problems of producing NiTi parts by SLM.

Corrosion Behavior of Additive Manufactured Ti-6Al-4V Alloy in NaCl Solution

NASA Astrophysics Data System (ADS)

Yang, Jingjing; Yang, Huihui; Yu, Hanchen; Wang, Zemin; Zeng, Xiaoyan

2017-07-01

The microstructures, potentiodynamic curves, and electrochemical impedance spectroscopy are characterized for Ti-6Al-4V samples produced by selective laser melting (SLM), SLM followed by heat treatment (HT), wire and arc additive manufacturing (WAAM), and traditional rolling to investigate their corrosion behaviors. Results show that the processing technology acts a significant role in controlling the microstructures, which in turn directly determine their corrosion resistance. The order of corrosion resistance of these samples is SLM < WAAM < rolling < SLM+HT. Among these microstructural factors for influencing corrosion resistance, type of constituent phase is the main one, followed by grain size, and the last is morphology. Finally, the application potentials of additive manufactured Ti-6Al-4V alloy are verified in the aspect of corrosion resistance.

Tissue engineering the mechanosensory circuit of the stretch reflex arc: sensory neuron innervation of intrafusal muscle fibers.

PubMed

Rumsey, John W; Das, Mainak; Bhalkikar, Abhijeet; Stancescu, Maria; Hickman, James J

2010-11-01

The sensory circuit of the stretch reflex arc, composed of specialized intrafusal muscle fibers and type Ia proprioceptive sensory neurons, converts mechanical information regarding muscle length and stretch to electrical action potentials and relays them to the central nervous system. Utilizing a non-biological substrate, surface patterning photolithography and a serum-free medium formulation a co-culture system was developed that facilitated functional interactions between intrafusal muscle fibers and sensory neurons. The presence of annulospiral wrappings (ASWs) and flower-spray endings (FSEs), both physiologically relevant morphologies in sensory neuron-intrafusal fiber interactions, were demonstrated and quantified using immunocytochemistry. Furthermore, two proposed components of the mammalian mechanosensory transduction system, BNaC1 and PICK1, were both identified at the ASWs and FSEs. To verify functionality of the mechanoreceptor elements the system was integrated with a MEMS cantilever device, and Ca(2+) currents were imaged along the length of an axon innervating an intrafusal fiber when stretched by cantilever deflection. This system provides a platform for examining the role of this mechanosensory complex in the pathology of myotonic and muscular dystrophies, peripheral neuropathy, and spasticity inducing diseases like Parkinson's. These studies will also assist in engineering fine motor control for prosthetic devices by improving our understanding of mechanosensitive feedback. Copyright (c) 2010 Elsevier Ltd. All rights reserved.

Safety of spray-dried powder formulated Pseudomonas fluorescens strain CL145A exposure to subadult/adult unionid mussels during simulated open-water treatments

USGS Publications Warehouse

Luoma, James A.; Weber, Kerry L.; Waller, Diane L.; Wise, Jeremy K.; Mayer, Denise A.; Aloisi, Douglas B.

2015-01-01

After exposure, the mussels were consolidated into wire mesh cages and placed in the Black River for a 27-28 day postexposure period, after which time survival of mussels was assessed. Of the 1,170 mussels tested in the study, 3 were confirmed dead and 5 were not recovered and treated as mortalities in the analysis. The effect and interactions of species, SDP exposure concentration, and SDP exposure duration were analyzed and did not affect mussel survival (p > 0.98). The results from this study indicate that SDP exposure at the maximum approved open-water concentration of 100 mg/L for up to 3 times the maximum approved open-water exposure duration of 8 hours (in other words for 24 hours of exposure) is unlikely to reduce survival of subadult or adult mussels.

Novel perovskite coating of strontium zirconate in Inconel substrate

NASA Astrophysics Data System (ADS)

Venkatesh, G.; Blessto, B.; Rao, C. Santhosh Kumar; Subramanian, R.; Berchmans, L. John

2018-02-01

Thermal Barrier Coatings (TBC) provides a low thermal conductivity barrier to heat transfer from the hot gas in the engine to the surface of the coated alloy component. SrZrO3 powder are prepared by Sol Gel synthesis method. The synthesized powder sample is characterized by X Ray Diffraction Technique (XRD), Scanning Electron Microscope (SEM) and Transmission Electron Microscope (TEM) and the results are interpreted. The Polycrystalline nature of SrZrO3 is confirmed and lattice spacing are determined in XRD. SEM shows sub-micron sized particles and a fringed pattern is observed in TEM. The IN718 specimen is Wire Cut and Sand Blasted. A SrZrO3 double layer is coated over the Inconel specimen through a Bond Coat made of NiCoCrAlY by Plasma spraying Process and also characterized. SEM analysis of the Coating shows diffusion of Fe, Sr into the substrate.

'Beautiful' unconventional synthesis and processing technologies of superconductors and some other materials.

PubMed

Badica, Petre; Crisan, Adrian; Aldica, Gheorghe; Endo, Kazuhiro; Borodianska, Hanna; Togano, Kazumasa; Awaji, Satoshi; Watanabe, Kazuo; Sakka, Yoshio; Vasylkiv, Oleg

2011-02-01

Superconducting materials have contributed significantly to the development of modern materials science and engineering. Specific technological solutions for their synthesis and processing helped in understanding the principles and approaches to the design, fabrication and application of many other materials. In this review, we explore the bidirectional relationship between the general and particular synthesis concepts. The analysis is mostly based on our studies where some unconventional technologies were applied to different superconductors and some other materials. These technologies include spray-frozen freeze-drying, fast pyrolysis, field-assisted sintering (or spark plasma sintering), nanoblasting, processing in high magnetic fields, methods of control of supersaturation and migration during film growth, and mechanical treatments of composite wires. The analysis provides future research directions and some key elements to define the concept of 'beautiful' technology in materials science. It also reconfirms the key position and importance of superconductors in the development of new materials and unconventional synthesis approaches.

High-Performance Polyimide Powder Coatings

NASA Technical Reports Server (NTRS)

2008-01-01

Much of the infrastructure at Kennedy Space Center and other NASA sites has been subjected to outside weathering effects for more than 40 years. Because much of this infrastructure has metallic surfaces, considerable effort is continually devoted to developing methods to minimize the effects of corrosion on these surfaces. These efforts are especially intense at KSC, where offshore salt spray and exhaust from Solid Rocket Boosters accelerate corrosion. Coatings of various types have traditionally been the choice for minimizing corrosion, and improved corrosion control methods are constantly being researched. Recent work at KSC on developing an improved method for repairing Kapton (polyimide)-based electrical wire insulation has identified polyimides with much lower melting points than traditional polyimides used for insulation. These lower melting points and the many other outstanding physical properties of polyimides (thermal stability, chemical resistance, and electrical properties) led us to investigate whether they could be used in powder coatings.

Study of factors governing oil-water separation process using TiO₂ films prepared by spray deposition of nanoparticle dispersions.

PubMed

Gondal, Mohammed A; Sadullah, Muhammad S; Dastageer, Mohamed A; McKinley, Gareth H; Panchanathan, Divya; Varanasi, Kripa K

2014-08-27

Surfaces which possess extraordinary water attraction or repellency depend on surface energy, surface chemistry, and nano- and microscale surface roughness. Synergistic superhydrophilic-underwater superoleophobic surfaces were fabricated by spray deposition of nanostructured TiO2 on stainless steel mesh substrates. The coated meshes were then used to study gravity driven oil-water separation, where only the water from the oil-water mixture is allowed to permeate through the mesh. Oil-water separation efficiencies of up to 99% could be achieved through the coated mesh of pore sizes 50 and 100 μm, compared to no separation at all, that was observed in the case of uncoated meshes of the same material and pore sizes. An adsorbed water on the TiO2 coated surface, formation of a water-film between the wires that form the mesh and the underwater superoleophobicity of the structured surface are the key factors that contribute to the enhanced efficiency observed in oil-water separation. The nature of the oil-water separation process using this coated mesh (in which the mesh allows water to pass through the porous structure but resists wetting by the oil phase) minimizes the fouling of mesh so that the need for frequent replacement of the separating medium is reduced. The fabrication approach presented here can be applied for coating large surface areas and to develop a large-scale oil-water separation facility for oil-field applications and petroleum industries.

Ultimate intrinsic-coercivity samarium-cobalt magnet: An Earth-based feasibility study for space-shuttle missions. [containerless melts

NASA Technical Reports Server (NTRS)

Das, D. K.; Kumar, K.; Frost, R. T.; Chang, C. W.

1980-01-01

Techniques for containerless melting and solidification of the samarium-cobalt alloy without excessive oxidation were developed. The rationale for extending these experiments in a weightless environment is also discussed. The effect of oxygen content from 0.15 to 0.63 weight percent and grain size in the range of 2 to 10 micrometers has been examined on arc-plasma-sprayed SmCo5 magnets. Contrary to expectations, the larger grain sizes tended to improve the coercivities. This was attributed to an increase in homogeneity resulting from higher temperature treatments used to produce larger grain size. No significant differences in coercivity were observed on the basis of oxygen content in the range examined. It is expected that more meaningful data on the relationship between oxygen content and coercivity will be seen when the oxygen content can be lowered to less than 0.1 weight percent.

Surface hardening of titanium alloys with melting depth controlled by heat sink

DOEpatents

Oden, Laurance L.; Turner, Paul C.

1995-01-01

A process for forming a hard surface coating on titanium alloys includes providing a piece of material containing titanium having at least a portion of one surface to be hardened. The piece having a portion of a surface to be hardened is contacted on the backside by a suitable heat sink such that the melting depth of said surface to be hardened may be controlled. A hardening material is then deposited as a slurry. Alternate methods of deposition include flame, arc, or plasma spraying, electrodeposition, vapor deposition, or any other deposition method known by those skilled in the art. The surface to be hardened is then selectively melted to the desired depth, dependent on the desired coating thickness, such that a molten pool is formed of the piece surface and the deposited hardening material. Upon cooling a hardened surface is formed.

Plasma spraying method for forming diamond and diamond-like coatings

DOEpatents

Holcombe, Cressie E.; Seals, Roland D.; Price, R. Eugene

1997-01-01

A method and composition for the deposition of a thick layer (10) of diamond or diamond-like material. The method includes high temperature processing wherein a selected composition (12) including at least glassy carbon is heated in a direct current plasma arc device to a selected temperature above the softening point, in an inert atmosphere, and is propelled to quickly quenched on a selected substrate (20). The softened or molten composition (18) crystallizes on the substrate (20) to form a thick deposition layer (10) comprising at least a diamond or diamond-like material. The selected composition (12) includes at least glassy carbon as a primary constituent (14) and may include at least one secondary constituent (16). Preferably, the secondary constituents (16) are selected from the group consisting of at least diamond powder, boron carbide (B.sub.4 C) powder and mixtures thereof.

The Evaluation of a Modified Chrome Oxide Based High Temperature Solid Lubricant Coating for Foil Gas Bearings

NASA Technical Reports Server (NTRS)

DellaCorte, Chris

1998-01-01

This paper describes the friction and wear performance of PS304, a modified chrome oxide based coating, for foil gas bearings. PS304 contains 60 wt% NiCr binder, 20 wt% Cr2O3 hardener, and 10 wt% each Ag, and BaF2/CaF2 lubricants. For evaluation, the coating is plasma spray deposited onto test journals which are slid against a superalloy partial arc foil bearing. The test load was 10 KPa (1.5 psi) and the bearings were run under start/stop cyclic conditions. The data show good wear performance of the bearing, especially at temperatures above 25 deg. C. Bearing friction was moderate (micron approx. or equal to 0.4) over the entire temperature range. Based upon the results obtained, the PS304 coating has promise for high temperature, oil-free turbomachinery applications.

Experimental testing of flexible barriers for containment of debris flows

USGS Publications Warehouse

DeNatale, Jay S.; Iverson, Richard M.; Major, Jon J.; LaHusen, Richard G.; Fliegel, Gregg L.; Duffy, John D.

1999-01-01

In June 1996, six experiments conducted at the U.S. Geological Survey Debris Flow Flume demonstrated that flexible, vertical barriers constructed of wire rope netting can stop small debris flows. All experimental debris flows consisted of water-saturated gravelly sand with less than two percent finer sediment by weight. All debris flows had volumes of about 10 cubic meters, masses of about 20 metre tons, and impact velocities of 5 to 9 meters per second. In four experiments, the debris flow impacted pristine, unreformed barriers of varying design; in the other two experiments, the debris flow impacted barriers already loaded with sediment from a previous flow. Differences in barrier design led to differences in barrier performance. Experiments were conducted with barriers constructed of square-mesh wire-rope netting with 30centimeter, 20centimeter, and 15 centimeter mesh openings as well as 30centimeter diameter interlocking steel rings. In all cases, sediment cascading downslope at the leading edge of the debris flows tended to spray through the nets. Nets fitted with finer-mesh chain link or chicken wire liners contained more sediment than did unlined nets, and a ring net fitted with a synthetic silt screen liner contained nearly 100 percent of the sediment. Irreversible net displacements of up to 2 meters and friction brake engagement on the support and anchor cables dissipated some of the impact energy. However, substantial forces developed in the steel support columns and the lateral and tie-back anchor cables attached to these columns. As predicted by elementary mechanics, the anchor cables experienced larger tensile forces when the support columns were hinged at the base rather than bolted rigidly to the foundation. Measured loads in the lateral anchor cables exceeded those in the tie-back anchor cables and the load cell capacity of 45 kilo-Newtons. Measurements also indicated that the peak loads in the tie- back anchors were highly transient and occurred at the points of maximum momentum impulse to the net.

Cavitation Erosion in Hydraulic Turbine Components and Mitigation by Coatings: Current Status and Future Needs

NASA Astrophysics Data System (ADS)

Singh, Raghuvir; Tiwari, S. K.; Mishra, Suman K.

2012-07-01

Cavitation erosion is a frequently observed phenomenon in underwater engineering materials and is the primary reason for component failure. The damage due to cavitation erosion is not yet fully understood, as it is influenced by several parameters, such as hydrodynamics, component design, environment, and material chemistry. This article gives an overview of the current state of understanding of cavitation erosion of materials used in hydroturbines, coatings and coating methodologies for combating cavitation erosion, and methods to characterize cavitation erosion. No single material property fully characterizes the resistance to cavitation erosion. The combination of ultimate resilience, hardness, and toughness rather may be useful to estimate the cavitation erosion resistance of material. Improved hydrodynamic design and appropriate surface engineering practices reduce damage due to cavitation erosion. The coatings suggested for combating the cavitation erosion encompasses carbides (WC Cr2C3, Cr3C2, 20CrC-80WC), cermets of different compositions (e.g., 56W2C/Ni/Cr, 41WC/Ni/Cr/Co), intermetallic composites, intermetallic matrix composites with TiC reinforcement, composite nitrides such as TiAlN and elastomers. A few of them have also been used commercially. Thermal spraying, arc plasma spraying, and high velocity oxy-fuel (HVOF) processes have been used commercially to apply the coatings. Boronizing, laser surface hardening and cladding, chemical vapor deposition, physical vapor deposition, and plasma nitriding have been tried for surface treatments at laboratory levels and have shown promise to be used on actual components.

Microstructural evolution and precipitation behavior in heat affected zone of Inconel 625 and AISI 904L dissimilar welds

NASA Astrophysics Data System (ADS)

Senthur Prabu, S.; Devendranath Ramkumar, K.; Arivazhagan, N.

2017-11-01

In the present investigation an attempt has been made to join the dissimilar combination of Inconel 625 super alloy and super austenitic stainless steel (AISI 904L) using manual multi-pass continuous current gas tungsten arc (CCGTA) welding processes. Two different filler wires such as ERNiCrMo-4 and ERNiCrCoMo-1 have been used to compare the metallurgical properties of these welded joints. Both optical microscopy and scanning electron microscopy techniques were adopted to disseminate the microstructure traits of these weldments. Formation of secondary phases at the HAZ and weld interface of AISI 904L was witnessed while using the ERNiCrCoMo-1 filler, along with Solidification Grain Boundary (SGB) and Migrated Grain Boundary (MGB) were also observed at the weld zone.

A Wireless Fluid-Level Measurement Technique

NASA Technical Reports Server (NTRS)

Woodard, Stanley E.; Taylor, Bryant D.

2006-01-01

This paper presents the application of a recently developed wireless measurement acquisition system to fluid-level measurement. This type of fluid-level measurement system alleviates many shortcomings of fluid-level measurement methods currently being used, including limited applicability of any one fluid-level sensor design. Measurement acquisition shortcomings include the necessity for power to be supplied to each sensor and for the measurement to be extracted from each sensor via a physical connection to the sensor. Another shortcoming is existing measurement systems require that a data channel and signal conditioning electronics be dedicated to each sensor. Use of wires results in other shortcomings such as logistics needed to add or replace sensors, weight, potential for electrical arcing and wire degradations. The fluid level sensor design is a simple passive inductor-capacitor circuit that is not subject to mechanical failure that is possible when float and lever-arm systems are used. Methods are presented for using the sensor in caustic, acidic or cryogenic fluids. Oscillating magnetic fields are used to power the sensor. Once electrically excited, the sensor produces a magnetic field response. The response frequency corresponds to the amount to fluid within the capacitor s electric field. The sensor design can be modified for measuring the level of any fluid or fluent substance that can be stored in a non-conductive reservoir. The interrogation method for discerning changes in the sensor response frequency is also presented.