aluminum lithium alloy 2195 fusion welding improvements ... · pdf filealuminum lithium alloy...

Aluminum Lithium Alloy 2195 FusionWelding Improvements with New Filler Wire

AMPET 2000Huntsville, AL

Carolyn RussellNASA

Marshall Space Flight CenterHuntsville, AL.256-544-2705

[email protected]

https://ntrs.nasa.gov/search.jsp?R=20010067248 2018-04-18T19:22:51+00:00Z

2195 Fusion Welding Improvements with New Filler Wire

2

Background

� Welding 2195 Aluminum Lithium for the Space ShuttleSuper Lightweight External Tank

Variable Polarity Plasma Arc Welding

NASA Space Shuttle


3

Background

FILLER WIRE DEVELOPMENT FOR

2195 ALUMINUM-LITHIUMLMSS/MSFC/RMC

(14) AL-CU BASED FILLER WIRES

FILLER WIRE DEVELOPMENT FOR

2195 ALUMINUM-LITHIUMLMSS/MSFC/RMC


CTTP COOPERATIVE IRADLMA/MSFC/RMC


CTTP COOPERATIVE IRADLMA/MSFC/RMC


SDS 3750ALUMINUM-LITHIUM WELD PROCESSES

ANDEQUIPMENT DEVELOPMENT

LMSS/MSFCB218 FILLER WIRE QUICK LOOK

SDS 3750ALUMINUM-LITHIUM WELD PROCESSES

ANDEQUIPMENT DEVELOPMENT

LMSS/MSFCB218 FILLER WIRE QUICK LOOK

PART II FILLER WIRE DEVELOPMENT FOR 2195 ALUMINUM-LITHIUMLMSS/MSFC/RMC


PART II FILLER WIRE DEVELOPMENT FOR 2195 ALUMINUM-LITHIUMLMSS/MSFC/RMC


C458 AIR FORCE AL-LI ALLOYWELD AND REPAIR EVALUATION

MSFCCHEMISTRY #16 FILLER WIRE

C458 AIR FORCE AL-LI ALLOYWELD AND REPAIR EVALUATION

MSFCCHEMISTRY #16 FILLER WIRE

1993

1998

1995

SDS 3763LMSS/MSFC

B218 REPAIR WELD EVALUATION

SDS 3763LMSS/MSFC

B218 REPAIR WELD EVALUATION

1999


4

2195T8M4 VPPA Weld Ultimate Tensile Strength

0

10

20

30

40

50

60

0.200"t4043

0.200"t B218

0.320"t 4043

0.320"t B218

SHAVED

AS-WELDED

UL

TIM

AT

E W

EL

D T

EN

SIL

E S

TR

EN

GT

H (

ksi)


5

2195T8M4 VPPA Weld Tensile Elongation

0

2

4

6

8

10

12

14

SHAVED

AS-WELDED

0.200"t4043

0.200"t B218

0.320"t 4043

0.320"t B218

% T

EN

SIL

E E

LO

NG

AT

ION

( 1

.0”

Gag

e)


6

VPPA Weld Grain Structure Comparison

4043 WELD FILLER WIRE B218 WELD FILLER WIRE

10X Original Magnification 10X Original Magnification

0.320t 2195 PLATE TO 2195 PLATE VPPAW


7

B218 VPPA Weld Grain Structure

VPPA WELD COVER PASS

VPPA WELD ROOT PASS

VPPA WELD ROOT PASS


0.200t 2195 PLATE TO 2195 PLATE VPPAW



8

B218 GTA Repair Weld Grain Structure

REPAIR WELD



VPPA WELD

ROOT PASS

GTA REPAIR WELD

R1 GTA Repair 0.200t 2195 PLATE TO 2195 PLATE VPPAW



9

VPPA WeldRepair Weld

Al-Li 2195

Al-Li 2195

Repair Weld Shrinkage

2195 Repair Weld Residual Stresses


10

-15

-10

-5

0

5

10

15

20

25

30

35

40

-3.5 -2.5 -1.5 -0.5 0.5 1.5 2.5 3.5

Distance From Repair Weld Midlength - Inches

Tra

nsv

erse

Res

idu

al S

tres

s -

Ksi

Along a Line Parallel to the WeldRoot Side MeasurementsPanel Clamped Flat

Unplanished Planished 70%

Welding Direction

Tran



11

Photostress of Unplanished Repair Weld

Photostress of Planished Repair Weld

R5 GTA Repair 0.200t 2195 PLATE TO 2195 PLATE VPPAW



12

Objective

• Assess B218 weld filler wire for Super Lightweight External Tankproduction, which could improve current production welding andrepair productivity.

• Perform a repair weld quick look evaluation between 4043/B218 andB218/B218 weld filler wire combinations. Evaluate tensile properties forplanished and unplanished conditions.

• Perform repair weld evaluation on structural simulation panel using4043/B218 and B218/B218 weld filler wire combinations. Evaluate tensileand simulated service fracture properties for planished and unplanishedconditions.

Approach


13

VPPA/GTA Repair Weld Quick Look

• 14” X 24” Standard Repair Weld Panel

WELDEND

MacroLH2 Tensile

RT Tensile

MacroLH2 Tensile

RT TensileRepair Weld A

(4” long)

Repair Weld B(4” long)

Manual GTA Repair Welding


14

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

4043/B218

0% PLAN.

4043/B218

70% PLAN.

B218/B218

70% PLAN.B218/B2180% PLAN.

4043/4043

70% PLAN.FSPAW

RE

PA

IR U

LT

IMA

TE

TE

NSI

LE

ST

RE

NG

TH

(ks

i)

0.200”t 2195T8M4 Repair Weld Ultimate Tensile Strength -Coupon Level

VPPA INITIAL WELD MANUAL GTA R5 FUSION LINE REPAIR

RT

LH2 Temp


15

0.00

2.00

4.00

6.00

8.00

10.00

12.00

RE

PA

IR W

EL

D T

EN

SIL

E E

LO

NG

AT

ION

(%

1.0

” G

AG

E)

4043/404370% PLAN.

*FSPAW

B218/B2180% PLAN.

B218/B21870% PLAN.

4043/B21870% PLAN.

4043/B2180% PLAN.

ROOM TEMP.

LH2 TEMP.


0.200”t 2195T8M4 Repair Weld Ultimate Tensile Elongation - Coupon Level


16

• 4043/B218 0% Planished

C009-CT01LH2 Temp. Tensile Test

62.5 ksi / 3.4%El. 1” gage

C008-RT02RT Tensile Test

36.2 ksi / 2.74%El. 1” gage

7X Original Magnification


0.200t 2195T8M4 VPPA/ GTA Repair Weld Metallography


17

C080-CT01LH2 Temp. Tensile Test

68.1 ksi / 7.40%El. 1” gage

C080-RT01RT Tensile Test

45.2 ksi / 9.75%El. 1” gage



• B218/B218 0% Planished

0.200t 2195T8M4 VPPA/ GTA Repair Weld Metallography


18

VPPA/ GTA Repair Weld Structural Simulation Panel Evaluation

• 19” X 48” Repair Weld Wide Panel

VPPA WELD

5” REPAIR WELD


19

0.200t 2195T8M4 Structural Simulation Panel Weld Tensile Strength (-423°F)

0

10

20

30

40

50

60

70

8040

43 V

PP

A

B21

8 V

PP

A

4043

/B21

80%

PL

AN

.

B21

8/B

218

0% P

LA

N.

B21

8/B

218

70%

PL

AN

.

4043

/B21

870

% P

LA

N.

UL

TIM

AT

E T

EN

SIL

E S

TR

EN

GT

H (

ksi)

4043

/404

3P

LA

TE

/EX

TR

.70

% P

LA

N.

FSP

AW

52 ksi LH2 VPPAALLOWABLE REQ.

38 ksi LH2 REPAIR ALLOWABLE REQ.

30 ksi RT REPAIR ALLOWABLE REQ.

40 ksi RT VPPAALLOWABLE REQ.

VPPA INITIALWELDS



20

0.320t 2195T8M4 Structural Simulation Panel Weld Tensile Strength (-423°F)

0

10

20

30

40

50

60

7040

43 V

PP

A

B21

8 V

PP

A

4043

/B21

80%

PL

AN

.

B21

8/B

218

0% P

LA

N.

B21

8/B

218

70%

PL

AN

.

4043

/B21

870

% P

LA

N.

UL

TIM

AT

E T

EN

SIL

E S

TR

EN

GT

H (

ksi)

49.4 ksi LH2 VPPAALLOWABLE REQ.

38 ksi LH2 REPAIR ALLOWABLE REQ.

30 ksi RT REPAIR ALLOWABLE REQ.

38 ksi RT VPPAALLOWABLE REQ.

4043

/404

3P

LA

TE

/EX

TR

.70

% P

LA

N.

VPPA INITIALWELDS



21

0.200t 2195T8M4 VPPA/GTA Repair Weld Simulated Service FractureToughness

10000

15000

20000

25000

30000

35000

40000

45000

50000

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

CRACK LENGTH (2c), IN.

a/2c=0.5, -320 F, 4043/B218 0%P

a/2c=0.5, -320 F, B218/B218 0%P

a/2c=0.5, -423 F, 4043/B218 0%P

a/2c=0.5, -423 F, B218/B218 0%P

a/2c=0.2, -320 F, B218/B218 0%P

a/2c=0.2, -423 F, 4043/B218 0%P

a/2c=0.2, -423 F, B218/B218 0%P

a/2c=0.5, -423 F, 4043/B218 70%P

a/2c=0.5, -423 F, B218/B218 70%P

a/2c=0.5, -423 F, B218/B218 70%P

Initial weld RT lower bound

B218 repairt=0.200"

GR

OS

S F

RA

CT

UR

E S

TR

ES

S, P

SI


22

0.320t 2195T8M4 VPPA/GTA Repair Weld Simulated Service FractureToughness

10000

15000

20000

25000

30000

35000

40000

45000

50000

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

CRACK LENGTH (2c), IN.

a/2c=0.5, 4043/4043 0%P

a/2c=0.5, B218/B218 0%P

a/2c=0.2, 4043/B218 0%P

a/2c=0.2, B218/B218 0%P

a/2c=0.5, 4043/B218 70%P

a/2c=0.2, 4043/B218 70%P

a/2c=0.5, B218/B218 70%P

a/2c=0.2, B218/B218 70%P"

Initial weld RT lower bound

B218 repairt=0.320”

-423 F test temperature

GR

OS

S F

RA

CT

UR

E S

TR

ES

S, P

SI


23

Conclusions

• B218 weld filler wire displayed higher repair weld tensile strength andductility compared to 4043.

• Unplanished and planished B218 repair welds exceeded the current SLWT4043 repair weld tensile strength requirement.

• B218 repair weld simulated service results surpassed 4043 repair weldsand were comparable to 2195 initial welds made with 4043.

• B218 displays a high potential for improving SLWT production throughincreased repair weldability and the reduction/elimination of planishingfor the removal of repair weld residual stresses.

aluminum lithium alloy 2195 fusion welding improvements ... · pdf filealuminum lithium alloy...

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