Robot welding process control

This final report documents the development and installation of software and hardware for Robotic Welding Process Control. Primary emphasis is on serial communications between the CYRO 750 robotic welder, Heurikon minicomputer running Hunter & Ready VRTX, and an IBM PC/AT, for offline programming and control and closed-loop welding control. The requirements for completion of the implementation of the Rocketdyne weld tracking control are discussed. The procedure for downloading programs from the Intergraph, over the network, is discussed. Conclusions are made on the results of this task, and recommendations are made for efficient implementation of communications, weld process control development, and advanced process control procedures using the Heurikon

Robot welding process control development task

The completion of, and improvements made to, the software developed during 1990 for program maintenance on the PC and HEURIKON and transfer to the CYRO, and integration of the Rocketdyne vision software with the CYRO is documented. The new programs were used successfully by NASA, Rocketdyne, and UAH technicians and engineers to create, modify, upload, download, and control CYRO NC programs

Welding process modelling and control

The research and analysis performed, and software developed, and hardware/software recommendations made during 1992 in development of the PC-based data acquisition system for support of Welding Process Modeling and Control is reported. A need was identified by the Metals Processing Branch of NASA Marshall Space Flight Center, for a mobile data aquisition and analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC-based system was chosen. The Welding Measurement System (WMS) is a dedicated instrument, strictly for the use of data aquisition and analysis. Although the WMS supports many of the functions associated with the process control, it is not the intention for this system to be used for welding process control

Investigation of Machine Design for Friction Stir Welding

The process of joining two pieces of metal together has not significantly changed over the last few decades. The basic idea used is to bring the pieces together and apply enough heat to melt the metal at the interface. The molten metal mixes and after cooling forms a strong joint. This process is called the fusion process. The most significant difference between the many fusion processes is how the heat is generated and applied. The Welding Institute (TWI), in Great Britain, has recently patented an innovative application of mechanical friction. TWI designed a tool and process called Friction Stir Welding (FSW) that uses friction to heat the metal to within a few hundred degrees Fahrenheit of melting, just to the point of being plastic-like. The tool then stirs the plasticized metal together forming a joint that has been shown to be as good or better than an equivalent fusion joint. The FSW process is well suited for the joining of the aluminum alloys used in the aerospace industry. The relatively low melting point of aluminum eliminates the requirements for exotic materials for pin tool design. The FSW process has been successfully used to join alloys such as 7075 which were before considered "unweldable", and aluminum-lithium 2195 which exhibits many problems when fusion welded. The objective this summer was to investigate the design of a FSW system that could take this process from the laboratory to the manufacturing floor. In particular, it was the goal of my NASA colleague to develop a concept for applying the FSW process to the manufacturing of aluminum cryogenic oxygen and hydrogen tanks, of the sort used to make the Shuttle External Tank

Automated data acquisition technology development:Automated modeling and control development

This report documents the completion of, and improvements made to, the software developed for automated data acquisition and automated modeling and control development on the Texas Micro rackmounted PC's. This research was initiated because a need was identified by the Metal Processing Branch of NASA Marshall Space Flight Center for a mobile data acquisition and data analysis system, customized for welding measurement and calibration. Several hardware configurations were evaluated and a PC based system was chosen. The Welding Measurement System (WMS), is a dedicated instrument strickly for use of data acquisition and data analysis. In addition to the data acquisition functions described in this thesis, WMS also supports many functions associated with process control. The hardware and software requirements for an automated acquisition system for welding process parameters, welding equipment checkout, and welding process modeling were determined in 1992. From these recommendations, NASA purchased the necessary hardware and software. The new welding acquisition system is designed to collect welding parameter data and perform analysis to determine the voltage versus current arc-length relationship for VPPA welding. Once the results of this analysis are obtained, they can then be used to develop a RAIL function to control welding startup and shutdown without torch crashing

Welding rework data acquisition and automation

Aluminum-Lithium is a modern material that NASA MSFC is evaluating as an option for the aluminum alloys and other aerospace metals presently in use. The importance of aluminum-lithium is in it's superior weight to strength characteristics. However, aluminum-lithium has produced many challenges in regards to manufacturing and maintenance. The solution to these problems are vital to the future uses of the shuttle for delivering larger payloads into earth orbit and are equally important to future commercial applications of aluminum-lithium. The Metals Processes Branch at MSFC is conducting extensive tests on aluminum-lithium which includes the collection of large amounts of data. This report discusses the automation and data acquisition for two processes: the initial weld and the repair. The new approach reduces the time required to collect the data, increases the accuracy of the data, and eliminates several types of human errors during data collection and entry. The same material properties that enhance the weight to strength characteristics of aluminum-lithium contribute to the problems with cracks occurring during welding, especially during the repair/rework process. The repairs are required to remove flaws or defects discovered in the initial weld, either discovered by x-ray, visual inspection, or some other type of nondestructive evaluation. It has been observed that cracks typically appear as a result of or beyond the second repair. MSFC scientists have determined that residual mechanical stress introduced by the welding process is a primary cause of the cracking. Two obvious solutions are to either prevent or minimize the stress introduced during the welding process, or remove or reduce the stress after the welding process and MSFC is investigating both of these

System for Controlling the Stirring Pin of a Friction Stir Welding Apparatus

A control is provided for a friction stir welding apparatus comprising a pin tool which includes a shoulder and a rotating pin extending outwardly from the shoulder of the pin tool and which, in use, is plunged into a workpiece formed contacting workpiece members to stir weld the members together. The control system controls the penetration of the pin tool into the workpiece members which are mounted on a support anvil. The control system includes a pin length controller for controlling pin length relative to the shoulder and for producing a corresponding pin length signal. A pin force sensor senses the force being exerted on the pin during welding and produces a corresponding actual pin force signal. A probe controller controls a probe extending outwardly from the pin, senses a parameter related to the distance between the probe and the supporting anvil and produces a corresponding probe signal. A workpiece standoff sensor senses the standoff distance between the workpiece and the standoff sensor and produces a corresponding standoff signal. A control unit receives the various signals, together with a weld schedule, and, based on these signals and the weld schedule, controls the pin length controller so as to control pin penetration into the workpiece

Thermal Diffusivity of Rhyolitic Glasses and Melts: Effects of Temperature, Crystals and Dissolved Water

Thermal diffusivity (D) was measured using laser-flash analysis on pristine and remelted obsidian samples from Mono Craters, California. These high-silica rhyolites contain between 0.013 and 1.10 wt% H2O and 0 to 2 vol% crystallites. At room temperature, D glass varies from 0.63 to 0.68 mm2 s−1, with more crystalline samples having higher D. As T increases, D glass decreases, approaching a constant value of ~0.55 mm2 s−1 near 700 K. The glass data are fit with a simple model as an exponential function of temperature and a linear function of crystallinity. Dissolved water contents up to 1.1 wt% have no statistically significant effect on the thermal diffusivity of the glass. Upon crossing the glass transition, D decreases rapidly near ~1,000 K for the hydrous melts and ~1,200 K for anhydrous melts. Rhyolitic melts have a D melt of ~0.51 mm2 s−1. Thermal conductivity (k = D·ρ·C P) of rhyolitic glass and melt increases slightly with T because heat capacity (C P) increases with T more strongly than density (ρ) and D decrease. The thermal conductivity of rhyolitic melts is ~1.5 W m−1 K−1, and should vary little over the likely range of magmatic temperatures and water contents. These values of D and k are similar to those of major crustal rock types and granitic protoliths at magmatic temperatures, suggesting that changes in thermal properties accompanying partial melting of the crust should be relatively minor. Numerical models of shallow rhyolite intrusions indicate that the key difference in thermal history between bodies that quench to obsidian, and those that crystallize, results from the release of latent heat of crystallization. Latent heat release enables bodies that crystallize to remain at high temperatures for much longer times and cool more slowly than glassy bodies. The time to solidification is similar in both cases, however, because solidification requires cooling through the glass transition in the first case, and cooling only to the solidus in the second

Thermal Diffusivity of Rhyolitic Glasses and Melts: Effects of Temperature, Crystals and Dissolved Water

Thermal diffusivity (D) was measured using laser-flash analysis on pristine and remelted obsidian samples from Mono Craters, California. These high-silica rhyolites contain between 0.013 and 1.10 wt% H2O and 0 to 2 vol% crystallites. At room temperature, D glass varies from 0.63 to 0.68 mm2 s−1, with more crystalline samples having higher D. As T increases, D glass decreases, approaching a constant value of ~0.55 mm2 s−1 near 700 K. The glass data are fit with a simple model as an exponential function of temperature and a linear function of crystallinity. Dissolved water contents up to 1.1 wt% have no statistically significant effect on the thermal diffusivity of the glass. Upon crossing the glass transition, D decreases rapidly near ~1,000 K for the hydrous melts and ~1,200 K for anhydrous melts. Rhyolitic melts have a D melt of ~0.51 mm2 s−1. Thermal conductivity (k = D·ρ·C P) of rhyolitic glass and melt increases slightly with T because heat capacity (C P) increases with T more strongly than density (ρ) and D decrease. The thermal conductivity of rhyolitic melts is ~1.5 W m−1 K−1, and should vary little over the likely range of magmatic temperatures and water contents. These values of D and k are similar to those of major crustal rock types and granitic protoliths at magmatic temperatures, suggesting that changes in thermal properties accompanying partial melting of the crust should be relatively minor. Numerical models of shallow rhyolite intrusions indicate that the key difference in thermal history between bodies that quench to obsidian, and those that crystallize, results from the release of latent heat of crystallization. Latent heat release enables bodies that crystallize to remain at high temperatures for much longer times and cool more slowly than glassy bodies. The time to solidification is similar in both cases, however, because solidification requires cooling through the glass transition in the first case, and cooling only to the solidus in the second