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All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Joining and Assembly of Bulk Metallic Glass Composites Through Capacitive Discharge

Bulk metallic glasses (BMGs), a class of amorphous metals defined as having a thickness greater than 1 mm, are being broadly investigated by NASA for use in spacecraft hardware. Their unique properties, attained from their non-crystalline structure, motivate several game-changing aerospace applications. BMGs have low melting temperatures so they can be cheaply and repeatedly cast into complex net shapes, such as mirrors or electronic casings. They are extremely strong and wear-resistant, which motivates their use in gears and bearings. Amorphous metal coatings are hard, corrosion-resistant, and have high reflectivity. BMG composites, reinforced with soft second phases, can be fabricated into energy-absorbing cellular panels for orbital debris shielding. One limitation of BMG materials is their inability to be welded, bonded, brazed, or fastened in a convenient method to form larger structures. Cellular structures (which can be classified as trusses, foams, honeycombs, egg boxes, etc.) are useful for many NASA, commercial, and military aerospace applications, including low-density paneling and shields. Although conventional cellular structures exhibit high specific strength, their porous structures make them challenging to fabricate. In particular, metal cellular structures are extremely difficult to fabricate due to their high processing temperatures. Aluminum honeycomb sandwich panels, for example, are used widely as spacecraft shields due to their low density and ease of fabrication, but suffer from low strength. A desirable metal cellular structure is one with high strength, combined with low density and simple fabrication. The thermoplastic joining process described here allows for the fabrication of monolithic BMG truss-like structures that are 90% porous and have no heat-affected zone, weld, bond, or braze. This is accomplished by welding the nodes of stacked BMG composite panels using a localized capacitor discharge, forming a single monolithic structure. This removes many complicated and costly fabrication steps. Moreover, the cellular structures detailed in this work are among the highest- strength and most energy-absorbent materials known. This implies that a fabricated structure made from these materials would have unequaled mechanical properties compared to other metal foams or trusses. The process works by taking advantage of the electrical properties of the matrix material in the metal-matrix composite, which in this case is a metallic glass. Due to the random nanoscale arrangement of atoms (without any grain boundaries), the matrix glass exhibits a near-constant electrical resistivity as a function of temperature. By placing the composite panels between two copper electrode plates and discharging a capacitor, the entire matrix of the panel can be heated to approximately 700 C in 10 milliseconds, which is above the alloy s solidus but below the liquidus. By designing the geometry of the panels into the shape of an egg box, the electrical discharge localizes only in the tips of each pyramidal cell. By applying a forging load during discharge, the nodes of the panels can be fused together into a single piece, which then dissipates heat through radiation back into a glassy state. This means that two panels can be metallurgically fused into one panel with no heat-affected zone, creating a seamless connection between panels. During the process, the soft metal particles (dendrites) that are uniformly distributed in the glassy matrix to increase the toughness are completely unaffected by the thermoplastic joining. The novelty is that a truss (or foam-like) structure can be formed with excellent energy- absorbing capabilities without the need for machining. The technique allows for large-scale fabrication of panels, well-suited for spacecraft shields or military vehicle door panels. Crystalline metal cellular structures cannot be fabricated using the thermoplastic joining technique described here. If metal panels were te assembled into a cellular structure, they would either have to be welded, brazed, bonded, or fastened together, creating a weak spot in the structure at each connection. Welded parts require a welding material to be added to the joint and exhibit a soft and weak heat-affected zone. Brazing and bonding do not form a metallurgical joint and thus exhibit low strengths, especially when the panels are pulled apart and fasteners require high-stress-concentration holes to be drilled. No equivalent rapid heating method exists for assembling metal panels together into cellular structures, and thus, those parts must be foamed, machined, or investment cast if they are to form a monolithic structure. If the crystalline panels were to be joined using capacitive discharge, as with a spot welder, their bond would be very weak, and the panels would have to be extremely thin. In contrast, the strength of joined BMG parts has been demonstrated to have strength comparable to the parent material. This technique opens up the possibility of using large-scale BMG hardware in spacecraft, military, or commercial applications.

Hofmann, Douglas C.↗
NASA NTRS2002

Dynamics of Sheared Granular Materials

This work focuses on the properties of sheared granular materials near the jamming transition. The project currently involves two aspects. The first of these is an experiment that is a prototype for a planned ISS (International Space Station) flight. The second is discrete element simulations (DES) that can give insight into the behavior one might expect in a reduced-g environment. The experimental arrangement consists of an annular channel that contains the granular material. One surface, say the upper surface, rotates so as to shear the material contained in the annulus. The lower surface controls the mean density/mean stress on the sample through an actuator or other control system. A novel feature under development is the ability to 'thermalize' the layer, i.e. create a larger amount of random motion in the material, by using the actuating system to provide vibrations as well control the mean volume of the annulus. The stress states of the system are determined by transducers on the non-rotating wall. These measure both shear and normal components of the stress on different size scales. Here, the idea is to characterize the system as the density varies through values spanning dense almost solid to relatively mobile granular states. This transition regime encompasses the regime usually thought of as the glass transition, and/or the jamming transition. Motivation for this experiment springs from ideas of a granular glass transition, a related jamming transition, and from recent experiments. In particular, we note recent experiments carried out by our group to characterize this type of transition and also to demonstrate/ characterize fluctuations in slowly sheared systems. These experiments give key insights into what one might expect in near-zero g. In particular, they show that the compressibility of granular systems diverges at a transition or critical point. It is this divergence, coupled to gravity, that makes it extremely difficult if not impossible to characterize the transition region in an earth-bound experiment. In the DE modeling, we analyze dynamics of a sheared granular system in Couette geometry in two (2D) and three (3D) space dimensions. Here, the idea is to both better understand what we might encounter in a reduced-g environment, and at a deeper level to deduce the physics of sheared systems in a density regime that has not been addressed by past experiments or simulations. One aspect of the simulations addresses sheared 2D system in zero-g environment. For low volume fractions, the expected dynamics of this type of system is relatively well understood. However, as the volume fraction is increased, the system undergoes a phase transition, as explained above. The DES concentrate on the evolution of the system as the solid volume fraction is slowly increased, and in particular on the behavior of very dense systems. For these configurations, the simulations show that polydispersity of the sheared particles is a crucial factor that determines the system response. Figures 1 and 2 below, that present the total force on each grain, show that even relatively small (10 %) nonuniformity of the size of the grains (expected in typical experiments) may lead to significant modifications of the system properties, such as velocity profiles, temperature, force propagation, and formation shear bands. The simulations are extended in a few other directions, in order to provide additional insight to the experimental system analyzed above. In one direction, both gravity, and driving due to vibrations are included. These simulations allow for predictions on the driving regime that is required in the experiments in order to analyze the jamming transition. Furthermore, direct comparison of experiments and DES will allow for verification of the modeling assumptions. We have also extended our modeling efforts to 3D. The (preliminary) results of these simulations of an annular system in zero-g environment will conclude the presentation.

Kondic, Lou↗