September 14, 2011Application of Electro-Spark Deposition for the Joining of Dissimilar MetalsJerry E. GouldTechnology Leader, Resistance and Solid-State WeldingEmail: [email protected]: 614.688.5121
Topics to be AddressedFunctionality of the electro-spark deposition processApplication for joints between Ni-based superalloys and refractory metalsObserved microstructuresResulting mechanical propertiesInterpretation of effective cooling ratesImplications for dissimilar joint metallurgy
Electro-Spark Deposition (ESD) ProcessESD processing characteristicsRepeat fire capacitive discharge power supplyDischarge pulse widths on the order of 35 sPeak currents on the order of 100s of ampsESD torchHand heldRotating electrodeShort circuit sparkingTransfer of small metal volumes (microns in diameter) to substrate
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-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
-0.0005250263
ASAP, no diode
Time (micro-seconds)
Current (A)
Sheet1
ASAP, no diode
time (microsec)Current (A)
0-0.0005250263
0.1953125-0.0005250263
0.390625-0.0005250263
0.5859375-0.0005250263
0.78125-0.0005250263
0.9765625-0.0005250263
1.171875-0.0005250263
1.3671875-0.0005250263
1.5625-0.0005250263
1.7578125-0.0005250263
1.953125-0.0005250263
2.1484375-0.0005250263
2.34375-0.0005250263
2.5390625-0.0005250263
2.734375-0.0005250263
2.9296875-0.0005250263
3.125-0.0005250263
3.3203125-0.0005250263
3.515625-0.0005250263
3.7109375-0.0005250263
3.90625-0.0005250263
4.1015625-0.0005250263
4.296875-0.0005250263
4.4921875-0.0005250263
4.6875-0.0005250263
4.8828125-0.0005250263
5.078125-0.0005250263
5.2734375-0.0005250263
5.46875-0.0005250263
5.6640625-0.0005250263
5.859375-0.0005250263
6.0546875-0.0005250263
6.253.4996499825
6.4453125-0.0005250263
6.640625-0.0005250263
6.8359375-0.0005250263
7.03125-0.0005250263
7.2265625-0.0005250263
7.421875-0.0005250263
7.6171875-0.0005250263
7.8125-0.0005250263
8.0078125-0.0005250263
8.203125-0.0005250263
8.3984375-0.0005250263
8.59375-0.0005250263
8.7890625-0.0005250263
8.984375-0.0005250263
9.1796875-0.0005250263
9.375-0.0005250263
9.5703125-0.0005250263
9.765625-0.0005250263
9.9609375-0.0005250263
10.15625-0.0005250263
10.3515625-0.0005250263
10.546875-0.0005250263
10.7421875-0.0005250263
10.9375-0.0005250263
11.1328125-0.0005250263
11.328125-0.0005250263
11.5234375-0.0005250263
11.71875-0.0005250263
11.9140625-0.0005250263
12.109375-0.0005250263
12.3046875-0.0005250263
12.5-0.0005250263
12.6953125-0.0005250263
12.890625-0.0005250263
13.0859375-0.0005250263
13.28125-0.0005250263
13.4765625-0.0005250263
13.671875-0.0005250263
13.8671875-0.0005250263
14.0625-0.0005250263
14.25781253.4996499825
14.4531256.9998249912
14.648437510.5
14.8437514.0001750088
15.039062517.5003500175
15.23437521.0005250263
15.429687524.500700035
15.62531.5010500525
15.820312535.0012250613
16.01562538.50140007
16.210937545.5017500875
16.4062552.502100105
16.601562559.5024501225
16.79687570.0029751488
16.992187577.0033251663
17.187584.0036751838
17.382812591.0040252013
17.57812598.0043752188
17.7734375105.0047252363
17.96875108.504900245
18.1640625115.5052502625
18.359375119.0054252713
18.5546875122.50560028
18.75126.0057752888
18.9453125129.5059502975
19.140625133.0061253063
19.3359375136.506300315
19.53125140.0064753238
19.7265625143.5066503325
19.921875147.0068253413
20.1171875150.50700035
20.3125150.50700035
20.5078125154.0071753588
20.703125157.5073503675
20.8984375157.5073503675
21.09375161.0075253763
21.2890625161.0075253763
21.484375164.507700385
21.6796875168.0078753938
21.875168.0078753938
22.0703125171.5080504025
22.265625171.5080504025
22.4609375175.0082254113
22.65625175.0082254113
22.8515625178.50840042
23.046875178.50840042
23.2421875182.0085754288
23.4375185.5087504375
23.6328125185.5087504375
23.828125185.5087504375
24.0234375189.0089254463
24.21875192.509100455
24.4140625192.509100455
24.609375192.509100455
24.8046875196.0092754638
25196.0092754638
25.1953125199.5094504725
25.390625199.5094504725
25.5859375199.5094504725
25.78125199.5094504725
25.9765625199.5094504725
26.171875203.0096254813
26.3671875203.0096254813
26.5625203.0096254813
26.7578125203.0096254813
26.953125203.0096254813
27.1484375203.0096254813
27.34375203.0096254813
27.5390625203.0096254813
27.734375203.0096254813
27.9296875203.0096254813
28.125203.0096254813
28.3203125203.0096254813
28.515625203.0096254813
28.7109375203.0096254813
28.90625199.5094504725
29.1015625203.0096254813
29.296875199.5094504725
29.4921875199.5094504725
29.6875199.5094504725
29.8828125196.0092754638
30.078125196.0092754638
30.2734375196.0092754638
30.46875196.0092754638
30.6640625192.509100455
30.859375192.509100455
31.0546875192.509100455
31.25189.0089254463
31.4453125189.0089254463
31.640625185.5087504375
31.8359375185.5087504375
32.03125185.5087504375
32.2265625182.0085754288
32.421875182.0085754288
32.6171875178.50840042
32.8125175.0082254113
33.0078125175.0082254113
33.203125171.5080504025
33.3984375171.5080504025
33.59375168.0078753938
33.7890625168.0078753938
33.984375164.507700385
34.1796875161.0075253763
34.375157.5073503675
34.5703125157.5073503675
34.765625154.0071753588
34.9609375150.50700035
35.15625147.0068253413
35.3515625143.5066503325
35.546875143.5066503325
35.7421875140.0064753238
35.9375136.506300315
36.1328125133.0061253063
36.328125129.5059502975
36.5234375126.0057752888
36.71875126.0057752888
36.9140625122.50560028
37.109375119.0054252713
37.3046875115.5052502625
37.5112.0050752538
37.6953125108.504900245
37.890625108.504900245
38.0859375101.5045502275
38.2812598.0043752188
38.476562598.0043752188
38.67187594.50420021
38.867187587.5038501925
39.062587.5038501925
39.257812584.0036751838
39.45312580.503500175
39.648437577.0033251663
39.8437573.5031501575
40.039062570.0029751488
40.23437566.50280014
40.429687563.0026251313
40.62559.5024501225
40.820312556.0022751138
41.01562556.0022751138
41.210937549.0019250963
41.4062545.5017500875
41.601562542.0015750788
41.79687542.0015750788
41.992187538.50140007
42.187535.0012250613
42.382812531.5010500525
42.57812528.0008750438
42.773437524.500700035
42.9687521.0005250263
43.164062521.0005250263
43.35937517.5003500175
43.554687514.0001750088
43.7510.5
43.94531256.9998249912
44.1406253.4996499825
44.33593753.4996499825
44.53125-0.0005250263
44.7265625-0.0005250263
44.921875-3.500700035
45.1171875-3.500700035
45.3125-3.500700035
45.5078125-3.500700035
45.703125-3.500700035
45.8984375-7.0008750438
46.09375-7.0008750438
46.2890625-7.0008750438
46.484375-7.0008750438
46.6796875-7.0008750438
46.875-7.0008750438
47.0703125-3.500700035
47.265625-3.500700035
47.4609375-0.0005250263
47.65625-0.0005250263
47.8515625-0.0005250263
48.0468753.4996499825
48.24218753.4996499825
48.43753.4996499825
48.63281253.4996499825
48.8281253.4996499825
49.02343753.4996499825
49.218753.4996499825
49.41406253.4996499825
49.6093753.4996499825
49.80468753.4996499825
503.4996499825
50.19531253.4996499825
50.3906253.4996499825
50.58593753.4996499825
50.781253.4996499825
50.9765625-0.0005250263
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51.7578125-3.500700035
51.953125-3.500700035
52.1484375-3.500700035
52.34375-3.500700035
52.5390625-3.500700035
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53.125-3.500700035
53.3203125-3.500700035
53.515625-7.0008750438
53.7109375-3.500700035
53.90625-3.500700035
54.1015625-3.500700035
54.296875-3.500700035
54.4921875-3.500700035
54.6875-3.500700035
54.8828125-3.500700035
55.078125-3.500700035
55.2734375-3.500700035
55.46875-3.500700035
55.6640625-3.500700035
55.859375-3.500700035
56.0546875-3.500700035
56.25-3.500700035
56.4453125-3.500700035
56.640625-3.500700035
56.8359375-3.500700035
57.03125-3.500700035
57.2265625-3.500700035
57.421875-3.500700035
57.6171875-3.500700035
57.8125-3.500700035
58.0078125-3.500700035
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58.3984375-3.500700035
58.59375-3.500700035
58.7890625-3.500700035
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59.1796875-3.500700035
59.375-3.500700035
59.5703125-3.500700035
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60.15625-3.500700035
60.3515625-3.500700035
60.546875-3.500700035
60.7421875-3.500700035
60.9375-3.500700035
61.1328125-3.500700035
61.328125-0.0005250263
61.5234375-0.0005250263
61.71875-0.0005250263
61.9140625-0.0005250263
62.109375-0.0005250263
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62.5-0.0005250263
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63.0859375-0.0005250263
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65.625-0.0005250263
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66.99218753.4996499825
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73.43753.4996499825
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74.21875-0.0005250263
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753.4996499825
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100-0.0005250263
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Sheet1
ASAP, no diode
Time (micro-seconds)
Current (A)
Sheet2
Sheet3
Firing Efficiency of Electro-Spark DepositionFiring rates defined by control systemIndividual pulse widths on the order of 10s of micro-secondsVariable contact pressures affect workpiece resistance and current flowSparking efficiency quality tool for assessing deposition characteristics70- 90% sparking efficiency deemed ideal
Electro-Spark Deposition (ESD) ProcessESD deposit characteristicsDeposit layers typically microns thickDeposition rates typically 105-oC/s)Non equilibrium solidification and suppression of solid-state transformations
Thermal Analysis of Various Localized Deposition Processes
Chart1
179.2480727152259.4379999825555.93857139111729.58666655193922.405275145
173.6687094061251.3626057193538.63415511281675.7507047953187886.281503105
168.1775573746243.4148856737521.60332644361622.7659044913181945.590517975
162.7746166207235.5948398457504.84608538361570.632265638176100.332319754
157.4598871444227.9024682353488.36243193281519.3497882353170350.506908444
152.2333689457220.3377708425472.15236609111468.9184722833164696.114284043
147.0950620247212.9007476673456.21588785851419.338317782159137.154446551
142.0449663812205.5913987097440.55299723511370.6093247313153673.62739597
137.0830820154198.4097239697425.16369422081322.7314931313148305.533132298
132.2094089272191.3557234473410.04797881561275.704822982143032.871655536
127.4239471166184.4293971425395.20585101961229.5293142833137855.642965683
122.7266965837177.6307450553380.63731083281184.2049670353132773.847062741
118.1176573283170.9597671857366.34235825511139.731781238127787.483946708
113.5968293506164.4164635337352.32099328651096.1097568913122896.553617585
109.1642126504158.0008340993338.57321592711053.3388939953118101.056075371
104.8198072279151.7128788825325.09902617681011.41919255113400.991320067
100.563613083145.5525978833311.8984240356970.3506525553108796.359351673
96.3956302157139.5199911017298.9714095036930.1332740113104287.160170189
92.315858626133.6150585377286.3179825808890.76705691899873.3937756144
88.324298314127.8378001913273.9381432671852.252001275395555.0601679495
84.4209492795122.1882160625261.8318915625814.588107083391332.1593471943
80.6058115227116.6663061513249.9992274671777.77537434287204.6913133489
76.8788850435111.2720704577238.4401509808741.813803051383172.6560664131
73.2401698419106.0055089817227.1546621036706.703393211379236.0536063871
69.6896659179100.8666217233216.1427608356672.44414482275394.8839332708
66.227373271595.8554086825205.4044471768639.036057883371649.1470470643
62.853291902890.9718698593194.9397211271606.479132395367998.8429477674
59.567421811686.2160052537184.7485826865574.77336835864443.9716353803
56.369762998181.5878148657174.8310318551543.918765771360984.5331099029
53.260315462277.0872986953165.1870686328513.915324635357620.5273713352
50.239079203972.7144567425155.8166930196484.7630449554351.9544196773
47.306054223268.4692890073146.7199050156456.461926715351178.814254929
44.461240520264.3517954897137.8967046208429.011969931348101.1068770905
41.704638094760.3619761897129.3470918351402.41317459845118.8322861617
39.036246946956.4998311073121.0710666585376.665540715342231.9904821426
36.456067076652.7653602425113.0686290911351.769068283339440.5814650333
33.96409848449.1585635953105.3397791328327.72375730236744.6052348337
31.56034116945.679441165797.8845167836304.529607771334144.0617915438
29.244795131642.327992953790.7028420436282.186619691331638.9511351636
27.017460371939.104218959383.7947549128260.69479306229229.2732656931
24.878336889736.008119182577.1602553911240.054127883326915.0281831324
GTAW
PAW
PTA
LBW
ESD
Temp (deg C)
Cooling rate (deg C/sec)
Sheet1
Heat Input (J/mm)K =11.4W/(m-Co)
GTAWPAWPTALBWESD0.0114J/(sec-mm-Co)
649.6062992126448.8188976378209.448818897667.3228346457223 =0.0031998653mm2/sec
Cp =0.435J/(g-Co)
Travel speeds (mm/sec)Hm =297.135j/g
GTAWPAWPTALBWESDxsp(ESD) =0.005mm
0.46181818180.66842105261.81428571430.90608187130.8071748879Tm =1400
To =25
TempGTAWPAWPTALBWESDRGTAWPAWPTALBWESD
1300179.2480727152259.4379999825555.93857139111729.586666551.94E+05014001400140014001400
1280173.6687094061251.3626057193538.63415511281675.75070479531.88E+050.00051339.71150181821347.970370991303.40150769561325.80029746331224.5484694341
1260168.1775573746243.4148856737521.60332644361622.76590449131.82E+050.0011281.89857637131265.70616450411106.0015251371211.65171044571053.5555809305
1240162.7746166207235.5948398457504.84608538361570.6322656381.76E+050.00151226.72202025681188.722191685939.68375358631107.990004613891.1429417671
1220157.4598871444227.9024682353488.36243193281519.34978823531.70E+050.0021174.05607439881116.666055567799.43887044351013.7956461801740.8001945623
1200152.2333689457220.3377708425472.15236609111468.91847228331.65E+050.00251123.78131823421049.210021534681.0874827616928.1552174699605.1669913869
1180147.0950620247212.9007476673456.21588785851419.3383177821.59E+050.0031075.7843284956986.0491904663581.1380757152850.2494604596485.913696246
1160142.0449663812205.5913987097440.55299723511370.60932473131.54E+050.00351029.9573578164926.8998164579496.6702145234779.3427914317383.7269386205
1140137.0830820154198.4097239697425.16369422081322.73149313131.48E+050.004986.1980319048871.4977567813425.2383113242714.774088146298.3889142789
1120132.2094089272191.3557234473410.04797881561275.7048229821.43E+050.0045944.4090641192819.5970429173364.7921821695655.9485803634228.933040098
1100127.4239471166184.4293971425395.20585101961229.52931428331.38E+050.005904.4979863616770.9685624872313.6113453159602.3306992038173.8399688642
1080122.7266965837177.6307450553380.63731083281184.20496703531.33E+050.0055866.3768952733725.3988428502270.2505910554553.4377615451131.2501909174
1060118.1176573283170.9597671857366.34235825511139.7317812381.28E+050.006829.9622127925682.6889279563233.4948168668508.834383152999.1627691245
1040113.5968293506164.4164635337352.32099328651096.10975689131.23E+050.0065795.1744601907642.6533407992202.3214939468468.12752901675.6022516098
1020109.1642126504158.0008340993338.57321592711053.33889399531.18E+050.007761.9380447687605.1191244869175.8694311254430.962121906158.7423165181
1000104.8198072279151.7128788825325.09902617681011.419192551.13E+050.0075730.1810584439569.9249555654153.4127445418397.017140851446.9839320216
980100.563613083145.5525978833311.8984240356970.35065255531.09E+050.008699.8350875128536.9203237809134.3391378547366.002150312838.9918495998
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GTAW
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Temp (deg C)
Cooling rate (deg C/sec)
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GTAW
PAW
PTA
LBW
ESD
Distance (mm)
Temp (deg C)
Sheet3
MBD001CE07E.unknown
MBD00BE3001.unknown
MBD00BDE2E8.unknown
MBD0013B23F.unknown
Chart2
14001400140014001400
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1226.72202025681188.722191685939.68375358631107.990004613891.1429417671
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1123.78131823421049.210021534681.0874827616928.1552174699605.1669913869
1075.7843284956986.0491904663581.1380757152850.2494604596485.913696246
1029.9573578164926.8998164579496.6702145234779.3427914317383.7269386205
986.1980319048871.4977567813425.2383113242714.774088146298.3889142789
944.4090641192819.5970429173364.7921821695655.9485803634228.933040098
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866.3768952733725.3988428502270.2505910554553.4377615451131.2501909174
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643.1189404022476.9271982388104.3540160719311.735111001630.2799359429
616.6278399391449.685194941592.6368878745288.028927894128.1295256028
591.3055939342424.12445547682.668257737266.339804904226.8109156085
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308.3269564854174.605223251429.661541052287.582856722125.0000101477
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285.0634671598157.521868145628.417206279978.027602574825.000001429
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263.7531195925142.421871084827.506812316969.956746129725.0000001819
GTAW
PAW
PTA
LBW
ESD
Distance (mm)
Temp (deg C)
Sheet1
Heat Input (J/mm)K =11.4W/(m-Co)
GTAWPAWPTALBWESD0.0114J/(sec-mm-Co)
649.6062992126448.8188976378209.448818897667.3228346457223 =0.0031998653mm2/sec
Cp =0.435J/(g-Co)
Travel speeds (mm/sec)Hm =297.135j/g
GTAWPAWPTALBWESDxsp(ESD) =0.005mm
0.46181818180.66842105261.81428571430.90608187130.8071748879Tm =1400
To =25
TempGTAWPAWPTALBWESDRGTAWPAWPTALBWESD
1300179.2480727152259.4379999825555.93857139111729.586666551.94E+05014001400140014001400
1280173.6687094061251.3626057193538.63415511281675.75070479531.88E+050.00051339.71150181821347.970370991303.40150769561325.80029746331224.5484694341
1260168.1775573746243.4148856737521.60332644361622.76590449131.82E+050.0011281.89857637131265.70616450411106.0015251371211.65171044571053.5555809305
1240162.7746166207235.5948398457504.84608538361570.6322656381.76E+050.00151226.72202025681188.722191685939.68375358631107.990004613891.1429417671
1220157.4598871444227.9024682353488.36243193281519.34978823531.70E+050.0021174.05607439881116.666055567799.43887044351013.7956461801740.8001945623
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1140137.0830820154198.4097239697425.16369422081322.73149313131.48E+050.004986.1980319048871.4977567813425.2383113242714.774088146298.3889142789
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1100127.4239471166184.4293971425395.20585101961229.52931428331.38E+050.005904.4979863616770.9685624872313.6113453159602.3306992038173.8399688642
1080122.7266965837177.6307450553380.63731083281184.20496703531.33E+050.0055866.3768952733725.3988428502270.2505910554553.4377615451131.2501909174
1060118.1176573283170.9597671857366.34235825511139.7317812381.28E+050.006829.9622127925682.6889279563233.4948168668508.834383152999.1627691245
1040113.5968293506164.4164635337352.32099328651096.10975689131.23E+050.0065795.1744601907642.6533407992202.3214939468468.12752901675.6022516098
1020109.1642126504158.0008340993338.57321592711053.33889399531.18E+050.007761.9380447687605.1191244869175.8694311254430.962121906158.7423165181
1000104.8198072279151.7128788825325.09902617681011.419192551.13E+050.0075730.1810584439569.9249555654153.4127445418397.017140851446.9839320216
980100.563613083145.5525978833311.8984240356970.35065255531.09E+050.008699.8350875128536.9203237809134.3391378547366.002150312838.9918495998
96096.3956302157139.5199911017298.9714095036930.13327401131.04E+050.0085670.8350329191505.9647729724118.1317573259337.654208633533.6977382642
94092.315858626133.6150585377286.3179825808890.7670569189.99E+040.009643.1189404022476.9271982388104.3540160719311.735111001630.2799359429
92088.324298314127.8378001913273.9381432671852.25200127539.56E+040.0095616.6278399391449.685194941592.6368878745288.028927894128.1295256028
90084.4209492795122.1882160625261.8318915625814.58810708339.13E+040.01591.3055939342424.12445547682.668257737266.339804904226.8109156085
88080.6058115227116.6663061513249.9992274671777.7753743428.72E+040.0105567.0987536411400.138210088174.1839875428246.489994113826.0229050302
86076.8788850435111.2720704577238.4401509808741.81380305138.32E+040.011543.9564233396377.62670832466.9604136319228.318090848125.5639520047
84073.2401698419106.0055089817227.1546621036706.70339321137.92E+040.0115521.830131815356.496737979660.8080412267211.677452845925.3034416787
82069.6896659179100.8666217233216.1427608356672.4441448227.54E+040.012500.67371072336.661178679555.5662403086196.434781642325.1593289995
80066.227373271595.8554086825205.4044471768639.03605788337.16E+040.0125480.4431794227318.03858744551.0987803065182.468848371925.0816327864
78062.853291902890.9718698593194.9397211271606.47913239536.80E+040.013461.0966359706300.552813828647.2900680619169.669348297925.040808563
76059.567421811686.2160052537184.7485826865574.7733683586.44E+040.0135442.594153822284.132642384444.0419759797157.93587020425.0199032635
74056.369762998181.5878148657174.8310318551543.91876577136.10E+040.014424.8976840188268.711460427141.2711659041147.176968386525.0094701197
72053.260315462277.0872986953165.1870686328513.91532463535.76E+040.0145407.9709624938254.226949191638.9068297281137.309326388325.0043956077
70050.239079203972.7144567425155.8166930196484.763044955.44E+040.015391.7794222238240.620796655836.8887806154128.25700284325.0019901726
68047.306054223268.4692890073146.7199050156456.46192671535.12E+040.0155376.2901099598227.838430428435.1658394363119.950750879925.000878919
66044.461240520264.3517954897137.8967046208429.01196993134.81E+040.016361.4716072768215.828769224333.6944699517112.327403490225.0003785931
64041.704638094760.3619761897129.3470918351402.4131745984.51E+040.0165347.2939557076204.543991570132.4376237463105.329318091725.0001590536
62039.036246946956.4998311073121.0710666585376.66554071534.22E+040.017333.7285857326193.939320483131.363762143398.903874266225.0000651694
60036.456067076652.7653602425113.0686290911351.76906828333.94E+040.0175320.7482494154183.972822966430.446027549993.003019298825.0000260409
58033.96409848449.1585635953105.3397791328327.7237573023.67E+040.018308.3269564854174.605223251429.661541052287.582856722125.0000101477
56031.56034116945.679441165797.8845167836304.52960777133.41E+040.0185296.4399136783165.799728798828.990806735682.603273579125.0000038562
54029.244795131642.327992953790.7028420436282.18661969133.16E+040.019285.0634671598157.521868145628.417206279978.027602574825.000001429
52027.017460371939.104218959383.7947549128260.6947930622.92E+040.0195274.175047864149.739339754627.926569956173.82231568225.0000005164
50024.878336889736.008119182577.1602553911240.05412788332.69E+040.02263.7531195925142.421871084827.506812316969.956746129725.0000001819
Sheet1
GTAW
PAW
PTA
LBW
ESD
Temp (deg C)
Cooling rate (deg C/sec)
Sheet2
GTAW
PAW
PTA
LBW
ESD
Distance (mm)
Temp (deg C)
Sheet3
MBD00BDE2E8.unknown
MBD00BE3001.unknown
MBD0013B23F.unknown
MBD001CE07E.unknown
Ni-Superalloy to Refractory Metal Joints for Space Nuclear PropulsionNuclear-powered space propulsionLunar-based powerGas cooled reactorBrayton cycle energy conversionRefractory metals at/near the reactorNickel-based superalloys at/near the turbineNeed for dissimilar materials transitions
Material Combinations of InterestRefractory to nickel-based superalloy jointsRefractory metal alloysMo-47.5 ReT-111 (Ta-8%W-2%Hf)Nickel-based superalloysHastelloy XMar M247Melting point suppression associated with eutecticsSolidification crackingLiquation crackingIntermetallic formationJoint ductilityPre-mature fracture
Electro-Spark Deposition Welding Trials Set-UpBonding procedureMachined joint prepESD fillJoint prep on reverse sideFinal fillPractice taken from EWI experienceSmall adaptations made to maintain surface quality
Electro-Spark Deposition Welding TrialsWelding of tensile specimensWeld prepDeposition practice:Hastelloy X electrode (1.5-mm diameter)40-F capacitance120-V charging voltage500-Hz firing rateThree specimens for materials combinationOne for metallographic sectionsFill patternsInternal fill qualityIntermetallic formationTwo samples each for mechanical testing
Joint Preparation and Electrode Orientation for the ESD Welds made in this StudyESD Weld Current Waveform Taken from a Representative Deposit
Chart1
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