Purpose: Virtually every Department of Defense (DoD) service relies on welded metal parts to perform their mission. This project replaces conventional welding power sources with commercially available state-of-the-art pulsed inverter power sources tied to programmable software packages. Tailoring the welding arc waveform based on the weld type, base material, and filler material and adjusting the pulsed power sources will minimize fume generation and provide an Environmental Safety and Occupational Health (ESOH) benefit. Description: Inverter power supplies take advantage of innovative solid-state electronics and machine construction that provide precise control of the welding waveform, optimizing the characteristics of the welding arc. Precision control prevents overheating and uncontrolled vaporization of the welding wire as it melts and transfers to the molten weld pool. The pulsed arc does not superheat the weld droplet, generating fewer fumes and minimizing spattering. Laboratory validation of specific power waveforms for fume constituent minimization in welding steel and high-nickel alloys for heavy vehicular equipment and shipboard operations will be conducted. Welds will be produced with optimized fume-minimization parameters for each power supply, then subjected to radiography for soundness, chemical analysis, and tensile and toughness testing. Benefits: The power inverters will reduce fugitive air emissions in DoD arc welding operations, thus saving initial capital costs and energy and life cycle costs. In addition, workers will have reduced exposure to emissions of hexavalent chromium and other hazardous air pollutant (HAP) metals. The solid state inverter construction is lighter and more compact than transformer-rectifiers, enabling easier transport to remote areas and permitting use in small spaces. (Anticipated Project Completion - 2007) Contact: Ms. Kathleen Paulson
NFESC, Code 425
1100 23rd Avenue
Port Hueneme, CA 93043-4370
Telephone: (805) 982-4984
Fax: (805) 982-1409
E-mail: paulsonkm@nfesc.navy.mil
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