Backup chill bar with new grooved dimensions improve welding of 2014-T6 aluminum. This groove geometry affords optimum chilling characteristics, reduces shrinkage and the weld bead is narrower and consistently free from impurities or voids

Black, F. J.

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October 1966	 Brief 66-10443 
NASA TECH BRIEF	
1 
NASA Tech Briefs are issued to summarize specific innovations derived from the U. S. space 
program and to encourage their commercial application. Copies are available to the public from 
the Clearinghouse for Federal Scientific and Technical Information, Springfield, Virginia 22151. 
New Backup-Bar Groove Configuration Improves Heliarc 
Welding of 2014-T6 Aluminum 
Wire Feed
Heliarc Welder 
The problem: 
To find the optimum groove size in backup chill 
bars when welding 2014-T6 aluminum in an effort 
to decrease weld defects, reduce shrinkage, and in-
crease tensile strength. 
The solution: 
Extensive testing showed that the best results were 
obtained with a backup chill bar with the following 
grooved dimensions: 0.187-inch width X 0.040-inch 
depth X 0.125-inch radius. 
How it's done: 
The incorporation of a shallow radius drop-through 
groove 0.040-inch deep by 0.187-inch wide in the 
backup bar produced a breakthrough in the welding 
of 0.051/0.064 thickness 2014 aluminum. This groove 
geometry afforded optimum chilling characteristics,
reduced shrinkage and the weld bead was narrower 
and consistently free from impurities or voids. 
Notes: 
1. With the use of this backup bar, 90 percent of 63 
inner structure welds were made in 1 welding pass. 
Also, in this same program, approximately 450 
inches of defect-free weld was accomplished in a 
a single pass. It has also been found that tensile 
strength has been increased by about 30 percent 
and shrinkage reduced by 50 percent. 
2. Inquiries concerning this innovation may be di-
rected to:
Technology Utilization Officer 
Manned Spacecraft Center 
Houston, Texas 77058 
Reference: B66-10443
(continued overleal) 
This document was prepared under the sponsorship of the National 
Aeronautics and Space Administration. Neither the United States 
Government nor any person acting on behalf of the United States
Government assumes any liability resulting from the use of the 
information contained in this document, or warrants that such use 
will be free from privately owned rights.
https://ntrs.nasa.gov/search.jsp?R=19660000442 2020-03-11T17:36:09+00:00Z
Patent status: 
No patent is contemplated by NASA. 
Source: F. J. Black
Of North American Aviation, Inc.

under contract to

Manned Spacecraft Center 
(MSC-806) 
Brief 66-10443	 Category 05


New backup-bar groove configuration improves heliarc welding of 2014-T6 aluminum

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