Manual welding operations remain totally dependent on the instincts of the operator and the operator's ability to collect information through normal sight and sound. The proposed innovation will apply modern data presentation technology to enhance the welder's perception of the welding situation. This "enhanced reality" will improve the quality of data available during a manual weld, thus improving the operator's ability to create predictable, repeatable welds. The operator will retain the ability to adjust parameters via foot pedal, hand switch or manipulation of the torch, but with greater control and precision. Heat input, surface travel speed and wire feed rate will be presented in real time. Methods to present the data will be researched in Phase 1: a head up type graphical display will be considered, possibly augmented by audible or tactile signals. The innovation supports the request for "Simulations of metals processes, utilizing graphic displays, correlated to actual process parameters and databases" under the subtopic "Welding and Related Metals Processing."NASA and its contractors use manual arc welding extensively for fabrication and repair of flight hardware. Commercial industry uses manual arc welding for a large proportion of its fabrication operations. Both these groups stand to benefit greatly from successful innovation of this "enhanced reality" for manual arc welding. Improved productivity, reduced costs and improved quality of product will make this product an attractive investment for all segments of American industry.Arc Welding Manual Virtual RealityPhase 2 conversion
