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At least 289 records · Page 16

All sources NASA NTRS DOE OSTI

NASA NTRS2013

Ultrasonic Low-Friction Containment Plate for Thermal and Ultrasonic Stir Weld Processes

The thermal stir welding (TSW) process is finding applications in fabrication of space vehicles. In this process, workpieces to be joined by TSW are drawn, by heavy forces, between "containment plates," past the TSW tool that then causes joining of the separate plates. It is believed that the TSW process would be significantly improved by reducing the draw force, and that this could be achieved by reducing the friction forces between the workpieces and containment plates. Based on use of high-power ultrasonics in metal forming processes, where friction reduction in drawing dies has been achieved, it is believed that ultrasonic vibrations of the containment plates could achieve similar friction reduction in the TSW process. By applying ultrasonic vibrations to the containment plates in a longitudinal vibration mode, as well as by mounting and holding the containment plates in a specific manner such as to permit the plates to acoustically float, friction between the metal parts and the containment plates is greatly reduced, and so is the drawing force. The concept was to bring in the ultrasonics from the sides of the plates, permitting the ultrasonic hardware to be placed to the side, away from the equipment that contains the thermal stir tooling and that applies clamping forces to the plates. Tests demonstrated that one of the major objectives of applying ultrasonics to the thermal stir system, that of reducing draw force friction, should be achievable on a scaled-up system.

Graff, Karl↗

NASA NTRS2016

Evaluation of Skin Friction Drag for Liner Applications in Aircraft

A parameter that is gaining significance in the evaluation of acoustic liner performance is the skin friction drag induced by air flow over the liner surface. Estimates vary widely regarding the amount of drag the liner induces relative to a smooth wall, from less than a 20% increase to nearly 100%, and parameters such as face sheet perforate hole diameter, percent open area, and sheet thickness are expected to figure prominently in the skin friction drag. Even a small increase in liner drag can impose an economic penalty, and current research is focused on developing 'low drag' liner concepts, with the goal being to approach the skin friction drag of a smooth wall. The issue of skin friction drag takes on greater significance as airframe designers investigate the feasibility of putting sound absorbing liners on the non-lifting surfaces of the wings and fuselage, for the purpose of reducing engine noise reflected and scattered toward observers on the ground. Researchers at the NASA Langley Research Center have embarked on investigations of liner skin friction drag with the aims of: developing a systematic drag measurement capability, establishing the drag of current liners, and developing liners that produce reduced drag without compromising acoustic performance. This paper discusses the experimental procedures that have been developed to calculate the drag coefficient based on the change in momentum thickness and the companion research program being carried out to measure the drag directly using a force balance. Liner samples that are evaluated include a solid wall with known roughness and conventional liners with perforated facesheets of varying hole diameter and percent open area.

Gerhold, Carl H.↗

DOE OSTI2015

General predictive model of friction behavior regimes for metal contacts based on the formation stability and evolution of nanocrystalline surface films.

The prediction of macro-scale friction and wear behavior based on first principles and material properties has remained an elusive but highly desirable target for tribologists and material scientists alike. Stochastic processes (e.g. wear), statistically described parameters (e.g. surface topography) and their evolution tend to defeat attempts to establish practical general correlations between fundamental nanoscale processes and macro-scale behaviors. We present a model based on microstructural stability and evolution for the prediction of metal friction regimes, founded on recently established microstructural deformation mechanisms of nanocrystalline metals, that relies exclusively on material properties and contact stress models. We show through complementary experimental and simulation results that this model overcomes longstanding practical challenges and successfully makes accurate and consistent predictions of friction transitions for a wide range of contact conditions. This framework not only challenges the assumptions of conventional causal relationships between hardness and friction, and between friction and wear, but also suggests a pathway for the design of higher performance metal alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Effects of Co{sub 3}O{sub 4} Addition on Friction and Dry Sliding Wear Characteristics of 8 mol% Yttria-Stabilized Cubic Zirconia

The aim of the present study was to investigate the influence of Co{sub 3}O{sub 4} additive on the microstructure, wear, and tribological properties of 8 mol% yttria-stabilized cubic zirconia (8YSZ) using a pin-on-disk tribometer, surface profilometer, hardness tester, and a scanning electron microscopy system. Specimens were produced by doping 1-15 wt.% Co{sub 3}O{sub 4} in 8YSZ using a colloidal process, sintering at 1500 °C for 1 h, and subsequent annealing at 1500 °C for 10 and 50 h. Microstructural analysis showed that Co{sub 3}O{sub 4} dissolved partially in 8YSZ, with the undissolved Co{sub 3}O{sub 4} precipitating as a secondary phase at the grain boundaries. Further, the addition of Co{sub 3}O{sub 4} enhanced the grain size. Wear tests were carried out using an Al{sub 2}O{sub 3} ball as the counterface against ceramic disk under dry sliding friction conditions at room temperature (24 °C). The wear volume of 8YSZ decreased from 0.30 to 0.11 mm{sup 3} as a result of the addition of 15 wt.% Co{sub 3}O{sub 4}. Additionally, friction coefficient of the 8YSZ significantly reduced from 0.55 to 0.17 at the beginning stage of the sliding after the addition of 15 wt.% Co{sub 3}O{sub 4}. This was because Co{sub 3}O{sub 4} creates a thin lubricating layer on the friction surface. In addition, the undoped and Co{sub 3}O{sub 4}-doped 8YSZ specimens exhibited abrasive wear under the dry sliding friction conditions, owing to the formation and propagation of microcracks, which resulted in the removal of material from the surface. The specific wear rate of 8YSZ decreased with increasing the Co{sub 3}O{sub 4} content. Thus, the addition of Co{sub 3}O{sub 4} to 8YSZ improves its wear resistance and surface topography.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Changes in the surface structure of the heterogeneous body (diorite) under friction

Raman, infrared, and photoluminescent spectroscopy has been used to study changes in the surface structure of quartz diorite caused by friction. Before friction, the diorite surface layer has contained mainly quartz and feldspar crystals. After friction, some quartz and feldspar crystals have been destructed and replaced by a newly formed hydromica mineral with a low friction coefficient such as illite.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2014

Protecting the radiation-damaged skin from friction: a mini review

Radiation-induced skin reactions are an unavoidable side effect of external beam radiation therapy, particularly in areas prone to friction and excess moisture such as the axilla, head and neck region, perineum and skin folds. Clinical studies investigating interventions for preventing or managing these reactions have largely focussed on formulations with moisturising, anti-inflammatory, anti-microbial and wound healing properties. However, none of these interventions has emerged as a consistent candidate for best practice. Much less emphasis has been placed on evaluating ways to protect the radiation-damaged skin from friction and excess moisture. This mini review analyses the clinical evidence for barrier products that form a protective layer by adhering very closely to the skin folds and do not cause further trauma to the radiation-damaged skin upon removal. A database search identified only two types of barrier products that fitted these criteria and these were tested in two case series and six controlled clinical trials. Friction protection was most effective when the interventions were used from the start of treatment and continued for several weeks after completion of treatment. Soft silicone dressings (Mepilex Lite and Mepitel Film) and Cavilon No Sting Barrier Film, but not Cavilon Moisturizing Barrier Cream, decreased skin reaction severity, most likely due to differences in formulation and skin build-up properties. It seems that prophylactic use of friction protection of areas at risk could be a worthwhile addition to routine care of radiation-damaged skin.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

DOE OSTI2021

Friction of Metals: A Review of Microstructural Evolution and Nanoscale Phenomena in Shearing Contacts

The friction behavior of metals is directly linked to the mechanisms that accommodate deformation. We examine the links between mechanisms of strengthening, deformation, and the wide range of friction behaviors that are exhibited by shearing metal interfaces. Specifically, the focus is on understanding the shear strength of nanocrystalline and nanostructured metals, and conditions that lead to low friction coefficients. Grain boundary sliding and the breakdown of Hall–Petch strengthening at the shearing interface are found to generally and predictably explain the low friction of these materials. While the following is meant to serve as a general discussion of the strength of metals in the context of tribological applications, one important conclusion is that tribological research methods also provide opportunities for probing the fundamental properties and deformation mechanisms of metals.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Stress and Friction Distribution around Slab Corner in Continuous Casting Mold with Different Corner Structures

The non-uniform friction and thermal stress in the mold are important as causes of the transverse cracks around strand corner. To analyze the stress distribution features around strand corner, a three-dimensional thermo-elastoplastic finite-element mold model with different corner structures (right-angle, big-chamfer, multi-chamfer, and fillet) was established. The temperature field in the mold was indirectly coupled through a three-dimensional fluid flow and heat transfer model. In addition, the non-uniform mold friction stress loaded on the strand surface was calculated through a friction model. The results show that the stress distribution on the shell is similar to the temperature distribution. The stress concentration appears in the strand corner and the lower part of wide face. The friction stress enhances the corner stress around the edge of the air-gap. For chamfered molds, the stress around the corner between the wide face and chamfer face is larger than that between the narrow face and chamfer face. Around the corner region, both the stress peak and the area of the large stress zone of the right-angle strand are the largest, while those of big-chamfered, multi-chamfered, and fillet strands decrease in that order. The stress peak position of the chamfered strands is closer to the mold exit than that of the right-angle strand. Compared with the use of the right-angle mold, the application of chamfered molds is able to reduce the stress concentration around the strand corner.

36 MATERIALS SCIENCE↗

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 OSTI2018

Influence of Temperature on Friction and Wear Characteristics of Polyaryletherketones and Their Composites Under Reciprocating Sliding Condition

The tribological behavior of different polyaryletherketones (PAEKs) and their composites was studied under reciprocating sliding conditions at room temperature as well as at elevated temperature (120 °C). The effect of glass, carbon fiber and solid lubricants (PTFE and graphite) filled in PAEK matrix was investigated at different normal loads. It was found that friction and wear characteristics are strongly influenced by the type of PAEK matrix and the material composition. The temperature has a more pronounced influence on the coefficient of friction and specific wear rates of PAEKs and their composites than the normal load. Friction and wear mechanisms are discussed, using scanning electron micrographs of the worn surfaces. A relationship between the average coefficient of friction and specific wear rates of PAEKs and their composites is also reported.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Laser Additive Manufacturing of (Ti-6Al-4V)/10 wt.% Ag Composite Using Spherical Powders to Reduce Wear and Friction

In order to extend the service lifetime of Ti-6Al-4V-based components, friction and wear behaviors of Ti-6Al-4V alloys needed to be further improved. Laser additive manufacturing with a moving laser beam was used to prepare (Ti-6Al-4V)/10 wt.% Ag samples, on a three-dimensional RC-SLM400 printer with laser powers of 2-10 kW. (Ti-6Al-4V)/10 wt.% Ag samples were successfully printed using spherical powders prepared by gas atomization process (SPGAP) and combustion reaction (SP-CR). The tribological properties of the as-prepared samples sliding against Si{sub 3}N{sub 4} balls were examined using a ball-on-disk tribometer. The results showed that the tribological behavior of (Ti-6Al-4V)/10 wt.% Ag printed by SP-CR was better than that of the sample printed by SPGAP. The low friction and reduced wear were mainly attributed to the formation of the lubrication layer containing large amounts of silver, which can exhibit an excellent deformation and plastic ductility. It effectively reduced the friction resistance and material loss and provided the good lubrication for 0-80 min, resulting in low friction and reduced wear of the samples prepared by SP-CR.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Mechanical and Frictional Performance of Ta and Ta-Ag Alloy Films Deposited at Different Sputtering Powers

The mechanical and tribological properties of tantalum and its alloy films are greatly influenced by their phase transformation. In this study, Ta and Ta-Ag films were prepared on carbon steel substrate by DC magnetron sputtering with various sputtering powers. The amorphous and nanocrystalline Ta and Ta-Ag film were produced at different sputtering powers from 40 to 110 W. The frictional properties of Ta and Ta-Ag films were investigated by rubbing against Si{sub 3}N{sub 4} ball from RT to 700 °C. The nanocrystalline Ta-Ag films shows higher hardness values (12 GPa) compared with amorphous phase. The nanocrystalline Ta90-Ag8 film shows a low friction coefficient of about 0.20-0.30 when rubbing against Si{sub 3}N{sub 4} ball at 700 °C. The segregation of Ag can effectively reduce friction coefficients of Ta-Ag film at 700 °C. The Ta-Ag films show high structure stability even after friction at 700 °C.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Tool-workpiece stick-slip conditions and their effects on torque and heat generation rate in the friction stir welding

Friction stir welding (FSW) has found increased applications in automotive and aerospace industries due to its advantages of solid-state bonding, no fusion and melting, and versatility in various working conditions and material combinations. However, the relationship among processing parameters, material properties, and bonding extent and fidelity remains largely empirical, primarily because of the lack of the mechanistic understanding of the tool-workpiece frictional behavior that affects our subsequent understanding of microstructural evolution and interface bonding formation. While the tool-workpiece stick-slip condition is believed to dictate the resulting torque and heat generation rate during the welding process, it remains rare and elusive to conduct a quantitative experimental measurement of such interfacial field. On the other hand, numerical simulations based on Computational Fluid Dynamics (CFD) rely on ad hoc assumptions of interfacial pressure and shear-stress conditions, but predictions can only be validated via the medium- and far-range temperature field which is known to be insensitive to the interfacial frictional behavior. This work first presents a comparison among two CFD-based simulation methodologies and the Coupled Eulerian Lagrangian (CEL) model in finite element method, the last of which uses the Coulomb friction so that the stick-slip is naturally developed. Based on the Hill-Bower similarity relationship in the contact analysis, an analytical model is developed here to prove why a constant stick-slip fraction will be developed in the steady state, to correlate the stick-slip fraction to processing parameters such as the tool spin rate, and further to derive dimensionless functions for torque and heat-generation-rate predictions. Pros and cons of various numerical approaches in predicting stick-slip are discussed, and our analytical model has been found to agree well with our numerical simulation and literature experimental results. These analyses provide the critical strain-rate and temperature fields that are needed for the bonding analysis in our future work.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Hydrogen accelerated fatigue crack growth of friction stir welded X52 steel pipe

Friction stir welded steel pipelines were tested in high pressure hydrogen gas to examine the effects of hydrogen accelerated fatigue crack growth. Fatigue crack growth rate (da/dN) vs. stress-intensity factor range (ΔK) relationships were measured for an X52 friction stir welded pipe tested in 21 MPa hydrogen gas at a frequency of 1 Hz and R = 0.5. Tests were performed on three regions: base metal (BM), center of friction stir weld (FSW), and 15 mm off-center of the weld. For all three material regions, tests in hydrogen exhibited accelerated fatigue crack growth rates that exceeded an order of magnitude compared to companion tests in air. Among tests in hydrogen, fatigue crack growth rates were modestly higher in the FSW than the BM and 15 mm off-center tests. Select regions of the fracture surfaces associated with specified ΔK levels were examined which revealed intergranular fracture in the BM and 15 mm off-center specimens but an absence of intergranular features in the FSW specimens. In conclusion, the X52 friction stir weld and base metal tested in hydrogen exhibited fatigue crack growth rate relationships that are comparable to those for conventional arc welded steel pipeline of similar strength found in the literature.

08 HYDROGEN↗

DOE OSTI2015

An analytical elastic plastic contact model with strain hardening and frictional effects for normal and oblique impacts

Impact between metallic surfaces is a phenomenon that is ubiquitous in the design and analysis of mechanical systems. We found that to model this phenomenon, a new formulation for frictional elastic–plastic contact between two surfaces is developed. The formulation is developed to consider both frictional, oblique contact (of which normal, frictionless contact is a limiting case) and strain hardening effects. The constitutive model for normal contact is developed as two contiguous loading domains: the elastic regime and a transitionary region in which the plastic response of the materials develops and the elastic response abates. For unloading, the constitutive model is based on an elastic process. Moreover, the normal contact model is assumed to only couple one-way with the frictional/tangential contact model, which results in the normal contact model being independent of the frictional effects. Frictional, tangential contact is modeled using a microslip model that is developed to consider the pressure distribution that develops from the elastic–plastic normal contact. This model is validated through comparisons with experimental results reported in the literature, and is demonstrated to be significantly more accurate than 10 other normal contact models and three other tangential contact models found in the literature.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Force measurement-based discontinuity detection during friction stir welding

Here, the objective of this work is to develop a method for detecting the creation of discontinuities ( i.e. , voids, volume defects) during friction stir welding. Friction stir welding is inherently cost effective, however, the need for significant weld inspection can make the process cost prohibitive. A new approach to weld inspection is required in which an in situ characterization of weld quality can be obtained, reducing the need for postprocess inspection. To this end, friction stir welds with subsurface voids and without voids were created. The subsurface voids were generated by reducing the friction stir tool rotation frequency and increasing the tool traverse speed in order to create “colder” welds. Process forces were measured during welding, and the void sizes were measured postprocess by computerized tomography ( i.e. , 3D X-ray imaging). Two parameters, based on frequency domain content and time-domain average of the force signals, were found to be correlated with void size. Criteria for subsurface void detection and size prediction were developed and shown to be in good agreement with experimental observations. Furthermore, with the proper choice of data acquisition system and frequency analyzer the occurrence of subsurface voids can be detected in real time.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Leak-tight crack repair for 304L stainless steel using friction surfacing

Here, friction surfacing (FS) was investigated as a method for sealing 50 μm wide thru-cracks in 3-mm-thick 304L stainless steel (304L) plate. Friction surfacing was performed using two sizes of 304L consumable rod, with diameters of 9.52 mm and 12.7 mm, on two substrate conditions (clean and oxidized). Friction surfacing was able to deposit a 600 μm thick coating and repair cracks to a depth of 100 μm - 200 μm below the original surface, when using the 12.7-mm-diameter consumable rod for both substrate conditions. Helium leak rates of 10 -10 atm-cc/s were achieved on crack repairs, designating them as leak-tight by the ANSI N14.5 standard. Optical and scanning electron microscopy were used to investigate the coating microstructure and bond interfaces. In this study, the 12.7-mm-diameter rod performed better with disruption of the oxide layer on the oxidized substrate and providing a more homogenous coating. Mechanical properties of the coated samples were evaluated by performing micro-indentation, tensile, bending, and adhesion testing. Higher hardness in the coatings was observed due to the fine equiaxed grains resulting from dynamic recrystallization. Complete consolidation of plastically deformed material on the substrate and a strong diffusion bond across the interface was observed. This was reflected in tensile and bending properties of the FS coatings being comparable to those of uncoated specimen. No delamination of the FS coating was observed during adhesion testing. The results demonstrate that friction surfacing is a viable option to seal cracks in stainless steels.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Characterization of boron carbide particulate reinforced in situ copper surface composites synthesized using friction stir processing

Friction stir processing has evolved as a novel solid state technique to fabricate surface composites. The objective of this work is to apply the friction stir processing technique to fabricate boron carbide particulate reinforced copper surface composites and investigate the effect of B{sub 4}C particles and its volume fraction on microstructure and sliding wear behavior of the same. A groove was prepared on 6 mm thick copper plates and packed with B{sub 4}C particles. The dimensions of the groove was varied to result in five different volume fractions of B{sub 4}C particles (0, 6, 12, 18 and 24 vol.%). A single pass friction stir processing was done using a tool rotational speed of 1000 rpm, travel speed of 40 mm/min and an axial force of 10 kN. Metallurgical characterization of the Cu/B{sub 4}C surface composites was carried out using optical microscope and scanning electron microscope. The sliding wear behavior was evaluated using a pin-on-disk apparatus. Results indicated that the B{sub 4}C particles significantly influenced the area, dispersion, grain size, microhardness and sliding wear behavior of the Cu/B{sub 4}C surface composites. When the volume fraction of B{sub 4}C was increased, the wear mode changed from microcutting to abrasive wear and wear debris was found to be finer. Highlights: • Fabrication of Cu/B{sub 4}C surface composite by friction stir processing • Analyzing the effect of B{sub 4}C particles on the properties of Cu/B4C surface composite • Increased volume fraction of B{sub 4}C particles reduced the area of surface composite. • Increased volume fraction of B{sub 4}C particles enhanced the microhardness and wear rate. • B{sub 4}C particles altered the wear mode from microcutting to abrasive.

36 MATERIALS SCIENCE↗