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Properties of Plasma Welds

Properties of Plasma Welds. Rafael Jaramillo Greg Angelides Linda McLaren. Overview. Experimental Objectives and Motivation Previous Work Experimental Design Results Future Work. Objectives and Motivation. Create a complete database of plasma welds

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Properties of Plasma Welds

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  1. Properties of Plasma Welds Rafael Jaramillo Greg Angelides Linda McLaren

  2. Overview • Experimental Objectives and Motivation • Previous Work • Experimental Design • Results • Future Work

  3. Objectives and Motivation • Create a complete database of plasma • welds • Study how speed and amperage affect the • weld attributes. • - width • - depth • - structure • Determine whether temperatures read with • a thermocouple correlate with Infrared • Camera readings.

  4. 1.5 mm/s 2.0 mm/s 3.0 mm/s 4.0 mm/s 4.5 mm/s 5.0 mm/s 1.5 mm/s 2.0 mm/s 3.0 mm/s 4.0 mm/s 4.5 mm/s Previous Work Two years ago an REU group created several plasma welds. Last year’s group organized them.

  5. Experimental Setup Fluke + Computer Plasma Welding Robot Camera Control + Television Infrared Camera Sample Holder

  6. While Welding…

  7. Experimental Design • Samples were cut and cleaned • Thermocouples were affixed • Sample was welded at specified current and speed • Temperature Data was recorded using a Fluke Hydra DAQ unit.

  8. Infrared Recordings were made during welding. • Cross sectional cut of samples was made and put into molds for microscope study.

  9. Polishing! • 5 step polishing process • Fine polishing necessary for viewing microscopic structures

  10. Finding IR Camera Range • Temp. range of IR camera had to be set before welding process • Tradeoff between visible temperature range and temperature resolution • Range set at 200 – 700 oC • Entire heating process could not be captured

  11. Sample Weld Results

  12. Welding Temperature Plot

  13. IR vs. Thermocouple Temperature Readings

  14. IR vs. Thermocouple Temperature Readings

  15. IR vs. Thermocouple Temperature Readings

  16. Sources of Error • Unreliable thermocouples: ultrasonic welding process flattened the leads • IR data could not be taken at thermocouple’s exact location • IR camera pixel intensity found to be unreliable

  17. Thermocouple Problem Good weld Bad weld

  18. IR Pixel Intensity Problem

  19. Future Work • Examine samples under microscope for structural changes due to welding • Determine accurate method for measuring temperature • Compare to numerical model for welding process using MathCad

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