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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Friction Stir Cutting for Decommissioning - 16130

Safe and cost effective decommissioning of redundant nuclear plant is a primary consideration to countries and companies with aging nuclear facilities. The wider media coverage of nuclear issues and strong public feeling is ensuring decommissioning options are also considered prior to development of new nuclear facilities. A project has been undertaken to demonstrate the feasibility of applying friction stir cutting, a non-fusion, non-machining, method of separating materials for size reduction of redundant metallic nuclear plant, specifically as a flexible low cost tool for plant dismantling. The research program was designed to provide a fast and effective approach to the assessment of process feasibility in stainless steels. Friction stir cutting may begin by traversing the rotating tool into the edge of the plate, or alternatively, by piercing the plate with a suitably profiled rotating friction stir cutting tool. Plate piercing trials were conducted to determine the down-force required to pierce the plate and to identify the appropriate tool tip profile for efficient piercing. The friction stir cutting process has been successfully demonstrated in 3 mm and 6 mm thick stainless steel plate. Provided sufficient torque is available, the friction stir cutting process is suitable for robotic application. The process is suitable for submerged applications such as the removal of pond furniture. Special attention was given towards any fume generation or particulate emissions during cutting. Friction stir cutting of bare steel plate does not generate fume, results in a relatively smooth edge profile and produces minimal loose debris. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2002

Deformation During Friction Stir Welding

Friction Stir Welding (FSW) is a solid state welding process that exhibits characteristics similar to traditional metal cutting processes. The plastic deformation that occurs during friction stir welding is due to the superposition of three flow fields: a primary rotation of a radially symmetric solid plug of metal surrounding the pin tool, a secondary uniform translation, and a tertiary ring vortex flow (smoke rings) surrounding the tool. If the metal sticks to the tool, the plug surface extends down into the metal from the outer edge of the tool shoulder, decreases in diameter like a funnel, and closes up beneath the pin. Since its invention, ten years have gone by and still very little is known about the physics of the friction stir welding process. In this experiment, an H13 steel weld tool (shoulder diameter, 0.797 in; pin diameter, 0.312 in; and pin length, 0.2506 in) was used to weld three 0.255 in thick plates. The deformation behavior during friction stir welding was investigated by metallographically preparing a plan view sections of the weldment and taking Vickers hardness test in the key-hole region.

Henry J. White↗
NASA NTRS2003

Self-Reacting Friction Stir Welding for Aluminum Alloy Circumferential Weld Applications

Friction stir welding is an innovative weld process that continues to grow in use, in the commercial, defense, and space sectors. It produces high quality and high strength welds in aluminum alloys. The process consists of a rotating weld pin tool that plasticizes material through friction. The plasticized material is welded by applying a high weld forge force through the weld pin tool against the material during pin tool rotation. The high weld forge force is reacted against an anvil and a stout tool structure. A variation of friction stir welding currently being evaluated is self-reacting friction stir welding. Self-reacting friction stir welding incorporates two opposing shoulders on the crown and root sides of the weld joint. In self-reacting friction stir welding, the weld forge force is reacted against the crown shoulder portion of the weld pin tool by the root shoulder. This eliminates the need for a stout tooling structure to react the high weld forge force required in the typical friction stir weld process. Therefore, the self-reacting feature reduces tooling requirements and, therefore, process implementation costs. This makes the process attractive for aluminum alloy circumferential weld applications. To evaluate the application of self-reacting friction stir welding for aluminum alloy circumferential welding, a feasibility study was performed. The study consisted of performing a fourteen-foot diameter aluminum alloy circumferential demonstration weld using typical fusion weld tooling. To accomplish the demonstration weld, weld and tack weld development were performed and fourteen-foot diameter rings were fabricated. Weld development consisted of weld pin tool selection and the generation of a process map and envelope. Tack weld development evaluated gas tungsten arc welding and friction stir welding for tack welding rings together for circumferential welding. As a result of the study, a successful circumferential demonstration weld was produced leading the way for future circumferential weld implementation.

Bjorkman, Gerry↗
DOE OSTI2018

Inverse Thermal Analysis of Ti-6Al-4V Friction Stir Welds Using Numerical-Analytical Basis Functions with Pseudo-Advection

Inverse thermal analysis of Ti-6Al-4V friction stir welds is presented that demonstrates application of a methodology using numerical-analytical basis functions and temperature-field constraint conditions. This analysis provides parametric representation of friction-stir-weld temperature histories that can be adopted as input data to computational procedures for prediction of solid-state phase transformations and mechanical response. These parameterized temperature histories can be used for inverse thermal analysis of friction stir welds having process conditions similar those considered here. Case studies are presented for inverse thermal analysis of friction stir welds that use three-dimensional constraint conditions on calculated temperature fields, which are associated with experimentally measured transformation boundaries and weld-stir-zone cross sections.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Physics-based process model approach for detecting discontinuity during friction stir welding

The goal of this work is to develop a method for detecting the creation of discontinuities during friction stir welding. This in situ weld monitoring method could significantly reduce the need for post-process inspection. A process force model and a discontinuity force model were created based on the state-of-the-art understanding of flow around an friction stir welding (FSW) tool. These models are used to predict the FSW forces and size of discontinuities formed in the weld. Friction stir welds with discontinuities and welds without discontinuities were created, and the differences in force dynamics were observed. In this paper, discontinuities were generated by reducing the tool rotation frequency and increasing the tool traverse speed in order to create "cold" welds. Experimental force data for welds with discontinuities and welds without discontinuities compared favorably with the predicted forces. The model currently overpredicts the discontinuity size.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Feasibility Evaluation of a Solid Phase Scalable HEA Cladding Manufacturing Route

First of a kind development result on two low-energy solid-phase processes applied on an irradiation-resistant alloy, NiCoFeCrCu 0.12 , are achieved and demonstrate moderate feasibility of successful tube fabrication using shear assisted processing and extrusion (ShAPE™) and friction stir layer deposition as a bulk manufacturing process. The scope of the work is performed in four phases: 1) direct tube manufacturing of the irradiation-resistant high-entropy alloy (HEA) composite with increased strength, 2) co-shear lining manufacturing process for the increased strength and corrosion-resistant, irradiation-tolerant HEAs, 3) ShAPE of the radially gradient corrosion resistance alloy, and 4) alloy development and fabrication enabled through friction stir additive manufacturing processes among others. This report describes the development activities from April to December 2023 to manufacture a direct customizable thin-walled tubular product from irradiation-tolerant composite high-entropy alloys (C-HEAs) while the overall project is continuing in 2024.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Evaluating the Potential for Remote In-Process Monitoring of Tool Wear in Friction Stir Welding of Stainless Steel

A wear characterization study was performed to determine the useful lifetime of Polycrystalline Cubic Boron Nitride tooling for the friction stir welding (FSW) of stainless steel samples in support of a nuclear repair welding research and development program. In-situ and ex-situ laser profilometry were utilized as primary methods of monitoring tool geometry degradation, and volumetric defects were detected through both non-destructive and destructive techniques, as repeated welds of a standard sample configuration were produced. The spectral content of weld forces were examined to search for indications of evolving material flow conditions, caused by significant tool wear, that would result in the formation of defects, and an artificial neural network was trained and evaluated as a means of automatically detecting these conditions. Here, the resulting performance constituted a successful demonstration of in-process monitoring of tool wear and weld quality in FSW of a high melting temperature, high hardness material.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Heat Control via Torque Control in Friction Stir Welding

In a proposed advance in friction stir welding, the torque exerted on the workpiece by the friction stir pin would be measured and controlled in an effort to measure and control the total heat input to the workpiece. The total heat input to the workpiece is an important parameter of any welding process (fusion or friction stir welding). In fusion welding, measurement and control of heat input is a difficult problem. However, in friction stir welding, the basic principle of operation affords the potential of a straightforward solution: Neglecting thermal losses through the pin and the spindle that supports it, the rate of heat input to the workpiece is the product of the torque and the speed of rotation of the friction stir weld pin and, hence, of the spindle. Therefore, if one acquires and suitably processes data on torque and rotation and controls the torque, the rotation, or both, one should be able to control the heat input into the workpiece. In conventional practice in friction stir welding, one uses feedback control of the spindle motor to maintain a constant speed of rotation. According to the proposal, one would not maintain a constant speed of rotation: Instead, one would use feedback control to maintain a constant torque and would measure the speed of rotation while allowing it to vary. The torque exerted on the workpiece would be estimated as the product of (1) the torque-multiplication ratio of the spindle belt and/or gear drive, (2) the force measured by a load cell mechanically coupled to the spindle motor, and (3) the moment arm of the load cell. Hence, the output of the load cell would be used as a feedback signal for controlling the torque (see figure).

Venable, Richard↗
NASA NTRS2003

2XXX Aluminum Self Reacting Friction Stir Weld Development

Weld process development are: (1) Execute a two-phased design of experiment (DOE) approach: process DOE to establish rotation and travel speeds and forge load;set-up DOE to establish allowable gap and centerline offset. (2) Determine the effect of process parameters on strength and weld quality: room and -320 deg F tensile testing; metalllurgical and NDE evaluation. (3) Weld quality goals: visual and radiographic acceptable; room temperature ultimate strength.

Brown, Randy J.↗
DOE OSTI2015

Thermal Management in Friction-Stir Welding of Precipitation-Hardening Aluminum Alloys

Process design and implementation in FSW is mostly dependent on empirical information gathered through experience. Basic science of friction stir welding and processing can only be complete when fundamental interrelationships between process control parameters and response variables and resulting weld microstructure and properties are established to a reasonable extent. It is known that primary process control parameters like tool rotation and translation rate and forge axis force have complicated and interactive relationships to the process response variables such as peak temperature, time at temperature etc. Of primary influence to the other process response parameters are temperature and its gradient at the deformation and heat affected zones. Through review of pertinent works in the literature and some experimental results from boundary condition work performed in precipitation hardening aluminum alloys this paper will partially elucidate the nature and effects of temperature transients caused by variation of thermal boundaries in Friction Stir Welding.

Friction Stir Welding↗
DOE OSTI2022

Understanding radiation effects in friction stir welded MA956 using ion irradiation and a rate theory model

We report an outstanding challenge in the manufacturing and joining of oxide dispersion strengthened steels is retaining the nanofeatures in the alloy throughout the fabrication and welding process. MA956 was friction stir welded with two different sets of welding parameters, resulting in a medium and high heat input. After welding, 5 MeV Fe ++ ion irradiations were performed at doses ranging from 50 to 200 dpa in the temperature range of 400 to 500°C. Post-irradiation characterization was performed with scanning transmission electron microscopy and energy-dispersive x-ray spectroscopy to investigate the Y-Al-O dispersoids, voids, and dislocations. After welding, the dispersoid microstructure coarsened, resulting in fewer and larger dispersoids regardless of heat input. After irradiation, the dispersoid behavior in the welded material was sensitive to temperature, exhibiting growth behavior attributed to Ostwald coarsening at 500 °C but a mixture of nucleation and more muted growth at 400 and 450 °C, attributed to competing mechanisms of radiation-enhanced diffusion and Ostwald coarsening. Void swelling correlated to heat input; being more prevalent in the welded conditions occurring at lower doses and in higher values relative to the base material. The low values of swelling despite microstructure coarsening caused by welding demonstrate the excellent swelling resistance of MA956, even after welding with the highest swelling values of 0.5% noted in the stir zone high heat input condition at 450 °C, 200 dpa. The dislocation behavior was inconsistent: the strongest trend was that network density was higher for welded versus base material, and an increase in loop diameter with temperature was observed. A rate theory model based on the observed microstructure suggests at high temperature interstitial loss to sinks was more likely to be dominant compared to mutual annihilation via point defect recombination, because of an increase of the radiation diffusion coefficient with temperature regardless of initial welded microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effects of thread interruptions on tool pins in friction stir welding of AA6061

In this paper, effects of pin thread and thread interruptions (flats) on weld quality and process response parameters during friction stir welding (FSW) of 6061 aluminium alloy were quantified. Otherwise, identical smooth and threaded pins with zero to four flats were adopted for FSW. Weldability and process response variables were examined. Results showed that threads with flats significantly improved weld quality and reduced in-plane forces. A three-flat threaded pin led to production of defect-free welds under all examined welding conditions. Spectral analyses of in-plane forces and weld cross-sectional analysis were performed to establish correlation among pin flats, force dynamics and defect formation. Finally, the lowest in-plane force spectra amplitudes were consistently observed for defect-free welds.

42 ENGINEERING↗
NASA NTRS2012

Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

Friction stir welding is a solid state welding process used in the fabrication of various aerospace structures. Self-reacting and conventional friction stir welding are variations of the friction stir weld process employed in the fabrication of cryogenic propellant tanks which are classified as pressurized structure in many spaceflight vehicle architectures. In order to address damage tolerance behavior associated with friction stir welds in these safety critical structures, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data describing fracture behavior, residual strength capability, and cyclic mission life capability of friction stir welds at ambient and cryogenic temperatures have been generated and will be presented in this paper. Fracture behavior will include fracture toughness and tearing (R-curve) response of the friction stir welds. Residual strength behavior will include an evaluation of the effects of lack of penetration on conventional friction stir welds, the effects of internal defects (wormholes) on self-reacting friction stir welds, and an evaluation of the effects of fatigue cycled surface cracks on both conventional and selfreacting welds. Cyclic mission life capability will demonstrate the effects of surface crack defects on service load cycle capability. The fracture data will be used to evaluate nondestructive inspection and proof test requirements for the welds.

McGill, Preston↗
DOE OSTI2024

A non-melting additive approach to structural repair of aluminum aircraft fastener holes

The damage to fastener holes in aerospace aluminum structures presents significant challenges for aircraft durability, and conventional bushing methods for repairing oversized holes often fall short due to the lack of metallurgical bonding and limited edge distance availability. This study investigates additive friction stir deposition, a non-melting additive process, as a viable alternative for the structural repair of aerospace fastener holes. The repair process, demonstrated on AA7050 (Al-Zn-Mg-Cu-Zr) hole structures, involves filling oversized holes with new material and machining to restore the original hole size. The repaired hole coupons are defect-free and exhibit good fatigue performance under fully reversed tension-compression loading (R = -1). At a nominal stress amplitude of 123.5 MPa, the average number of cycles to failure is 12,666 for unrepaired baseline coupons and 17,372 for effectively repaired coupons. Restoring complex geometries without compromising fatigue performance has been difficult in aerospace applications; this study marks the first demonstration of additive repair that consistently outperforms the unrepaired baseline coupons. Notably, the result is achieved through a low-energy, cost-effective solution without the need for post-repair heat treatment. Except for a few outliers, the post-repair fatigue performance generally remains inferior to that of undamaged, pristine coupons, likely due to precipitate evolution in AA7050 caused by the thermomechanical processing nature of additive friction stir deposition. This evolution weakens the repair region and the adjacent base material, leading to faster crack initiation and growth compared to the properly aged base material, AA7050-T7451.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Update on Investigations of Viability of Cold Spray and FSW as a Spent Nuclear Fuel Dry Storage Canister Mitigation Tool

The purpose of this work is to investigate the use of cold spray and friction stir welding or processing (FSW/P) for repair and mitigation of chloride-induced stress corrosion cracking (CISCC) in dry cask storage system (DCSS) canisters to ensure integrity far beyond their original license period. This report provides a viability analysis of cold spray and friction stir welding for repair and fabrication of DCSS canisters. This report presents experimental work and a research strategy to optimize and evaluate cold spray and FSW/P for CISCC resistance. The literature reports that the following three conditions must exist for CISCC to occur: tensile stress, corrosive environment, and susceptible material. These conditions must be understood and accounted for while evaluating CISCC susceptibility. Furthermore, non-obvious factors, such as surface conditions and geometric confinement, can dramatically increase the intensity of one or more of the three listed conditions for CISCC. Arc welding should be considered for either temporary or permanent repair when combined with a mitigation technology. It is known that alloys used in the existing inventory of spent nuclear fuel storage canisters become sensitized in areas around fusion welds. Technologies, such as cold spray or FSW, can mitigate the sensitization caused by fusion welds. FSW/P and cold spray, potential alternatives for fabrication and repair, are solid-phase processes. No melting occurs and the energy input can be controlled such that no harm is done to the base metal during these processes. FSW/P should be considered for use in new fabrication of canisters and repair of existing canisters. Low heat input and grain refinement result in material with improved mechanical properties and comparable generalized corrosion performance relative to base metal. FSW/P offers the potential of through-thickness CISCC resistance. Cold spray should be considered for production, mitigation, and repair of canisters. Cold spray has demonstrated the ability to deposit stainless steel, Inconel alloys, and other alloys on stainless steel 304L such that galvanic potential is matched and resistance to pitting is improved. The technical basis for cold spray mitigation and repair within the overpack using remote robotic equipment is established. A non-obvious application to the research community is the sealing of crevices. All reported instances of CISCC in the fielded nuclear applications were associated with crevice corrosion. This can be avoided by cold spraying to seal crevices. The bulk of the work planned for FY 2020 will be generating coupons for CISCC testing by collaborative projects at Pacific Northwest National Laboratory and Sandia National Laboratories. First an exploratory study will be executed that will include screening studies and process optimization. This task will identify the effect of process parameters on microstructure and CISCC resistance. Optimized parameters will be used to produce a smaller number of coupons for full testing and evaluation. Test methods for evaluating CISCC resistance must meet the following criteria: (1) normalized surface geometry and exposed process microstructure, (2) account for residual stresses, (3) be in a controlled and appropriate test environment, and (4) be numerically quantifiable and repeatable. Failure to meet these criteria could lead to results that cannot be used for comparative analysis of processes and materials.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Sparse Data Machine Learning Integration with Theory, Experiment and Uncertainty Quantification: Process-Structure-Property-Performance of Friction Deformation Processing

Computer vision and deep learning tools that advance the ability to establish processing-structure-property-performance (PSPP) relations are presented. The Bayesian binning method for image segmentation enables quantitative analysis of microstructural features in an automated way, while the analysis of shapes and relative orientation of these features reveals local deformation maps indicative of both, material flow and residual stresses due to materials processing. The deep learning method leads to the previous knowledge agnostic mapping of empirically observed microstructural zones in friction stir welding (FSW) process and synthetic microstructure generation capability that is statistically equivalent to experimentally collected data.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Process planning for hybrid manufacturing using additive friction stir deposition

Additive friction stir deposition (AFSD) provides a solid-state approach to metal deposition that does not rely on local melting and solidification, but rather on kinetic energy and plastic flow. Here, in this study, AFSD is combined with structured light scanning, turning, and milling to produce metal components while considering the unique requirements imposed by the hybrid manufacturing process sequences. Two demonstrations are presented which include: 1) a cylindrical build plate selection to enable coordinate system transfer between deposition and turning of a hollow cone; and 2) intermittent deposition-machining operations with structured light scanning to fabricate a two-sided hexagon-cylinder geometry.

36 MATERIALS SCIENCE↗