The commercial realization of a cost effective orbital weld inspection device depends on the establishment of a low-cost, reliable method of imaging the weld area inner and outer surfaces. TechnoLink proposes to investigate the development of a novel imaging device based on state-of-the-art micro-capacitive and eddy current sensing technology. The proposed sensor would result in surface visualization and thickness determination of the weld area. Furthermore, a preweld alignment check will be conducted. During the proposed Phase I effort, TechnoLink will demonstrate the applicability of this technology by conducting prototype sensor testing and developing data analysis algorithms that characterize typical weld flaws. The successful completion of Phase I will result in a preliminary design of an orbital weld inspection system. Completion of Phases II & III will yield a commercially available orbital welding system that also performs pre-weld alignment checks and post-weld inspection. This system will benefit NASA in both aircraft and space applications by eliminating costly rework due to improper set up, and by performing weld inspections real time without the need for off line shops or labs. Automatic orbital welding equipment is currently being used in the nuclear, aerospace pharmaceutical, chemical, and food processing industries. The aerospace applications include but are not limited to: spacecraft fuel, hydraulic, and propulsion lines; aircraft fuel and hydraulic lines; and rocket propulsion lines. Orbital welding produces higher quality welds in less time than manual techniques. It is still sensitive, however, to proper pre- weld setup, as any misalignment will yield a flawed weld. All required post-weld inspections must currently be performed in off line shops or labs, and are thus time consuming and expensive. The use of an orbital weld head with an integrated micro- capacitive and eddy current sensing system would eliminate any misalignment problems and significantly reduce post-weld inspection time. Both the Federal Government and private industry would benefit from the development of this technology through the reduced cost and time savings required to perform and inspect welds compared to current methods. Material waste would also be minimized by avoiding the need to rework flawed welds.
Keywords: Phase_I, NASA, Abstract, FY94
