Internal Friction Reduction Pin Tool for Friction Stir Welding
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Jordan A Larsen↗
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Internal Friction Reduction Tool (For Self-Reacting Friction Stir Welding)
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Josef Cobb↗
Experimental Investigation of Average Heat-Transfer and Friction Coefficients for Air Flowing in Circular Tubes Having Square-Thread-Type Roughness
An investigation of forced-convection heat transfer and associated pressure drops was conducted with air flowing through electrically heated Inconel tubes having various degrees of square-thread-type roughness, an inside diameter of 1/2 inch, and a length of 24 inches. were obtained for tubes having conventional roughness ratios (height of thread/radius of tube) of 0 (smooth tube), 0.016, 0.025, and 0.037 over ranges of bulk Reynolds numbers up to 350,000, average inside-tube-wall temperatures up to 1950deg R, and heat-flux densities up to 115,000 Btu per hour per square foot. Data The experimental data showed that both heat transfer and friction increased with increase in surface roughness, becoming more pronounced with increase in Reynolds number; for a given roughness, both heat transfer and friction were also influenced by the tube wall-to-bulk temperature ratio. Good correlation of the heat-transfer data for all the tubes investigated was obtained by use of a modification of the conventional Nusselt correlation parameters wherein the mass velocity in the Reynolds number was replaced by the product of air density evaluated at the average film temperature and the so-called friction velocity; in addition, the physical properties of air were evaluated at the average film temperature. The isothermal friction data for the rough tubes, when plotted in the conventional manner, resulted in curves similar to those obtained by other investigators; that is, the curve for a given roughness breaks away from the Blasius line (representing turbulent flow in smooth tubes) at some value of Reynolds number, which decreases with increase in surface roughness, and then becomes a horizontal line (friction coefficient independent of Reynolds number). A comparison of the friction data for the rough tubes used herein indicated that the conventional roughness ratio is not an adequate measure of relative roughness for tubes having a square-thread-type element. The present data, as well as those of other investigators, were used to isolate the influence of ratios of thread height to width, thread spacing to width, and the conventional roughness ratio on the friction coefficient. A fair correlation of the friction data was obtained for each tube with heat addition when the friction coefficient and Reynolds number were defined on the basis of film properties; however, the data for each tube retained the curve characteristic of that particular roughness. The friction data for all the rough tubes could be represented by a single line for the complete turbulence region by incorporating a roughness parameter in the film correlation. No correlation was obtained for the region of incomplete turbulence.
Sams, E. W.↗
Analog-computer investigation of effects of friction and preload on the dynamic longitudinal characteristics of a pilot-airplane combination
With an electric analog computer, an investigation has been made of the effects of control frictions and preloads on the transient longitudinal response of a fighter airplane during abrupt small attitude corrections. The simulation included the airplane dynamics, powered control system, feel system, and a simple linearized pseudopilot. Control frictions at the stick pivot and at the servo valve as well as preloads of the stick and valve were considered individually and in combinations. It is believed that the results which are presented in the form of time histories and vector diagrams present a more detailed illustration of the effects of stray forces and compensating forces in the longitudinal control system than has previously been available. Consistent with the results of previous studies, the present results show that any of thesefour friction and preload forces caused some deterioration of the response. However, even a small amount of valve friction caused an oscillatory pitching response during which the phasing of the valve friction was such that it caused energy to be fed into the pitching oscillation of the airplane. Of the other friction and preload forces which were considered, it was found that stick preload was close to 180 degrees out of phase with valve friction and thus could compensate in large measure for valve friction as long as the cycling of the stick encompassed the trim point. Either stick friction or valve preload provided a smaller stabilizing effect primarily through a reduction in the amplitude of the resultant force vector acting on the control system. Some data were obtained on the effects of friction when the damping or inertia of the control system or the pilot lag was varied.
Crane, Harold L↗
Analog-Computer Investigation of Effects of Friction and Preload on the Dynamic Longitudinal Characteristics of a Pilot-Airplane Combination
With an electric analog computer, an investigation has been made of the effects of control frictions and preloads on the transient longitudinal response of a fighter airplane during abrupt small attitude corrections. The simulation included the airplane dynamics, powered control system, feel system, and a simple linearized pseudopilot. Control frictions at the stick pivot and at the servo valve as well as preloads of the stick and valve were considered individually and in combinations. It is believed that the results which are presented in the form of time histories and vector diagrams present a more detailed illustration of the effects of stray forces and compensating forces in the longitudinal control system than has previously been available. Consistent with the results of previous studies, the present results show that any of these four friction and preload forces caused some deterioration of the response. However, even a small amount of valve friction caused an oscillatory pitching response during which the phasing of the valve friction was such that it caused energy to be fed into the pitching oscillation of the air-plane. Of the other friction and preload forces which were considered, it was found that stick preload was close to 180 deg. out of phase with valve friction and thus could compensate in large measure for valve friction as long as the cycling of the stick encompassed the trim point. Either stick friction or valve preload provided a smaller stabilizing effect primarily through a reduction in the amplitude of the resultant force vector acting on the control system. Some data were obtained on the effects of friction when the damping or inertia of the control system or the pilot lag was varied.
Crane, Harold L.↗
Mesoscale Modeling of Hydrogels Under Frictional Shear Stress
Hydrogels are three-dimensional networks of hydrophilic polymers often used as a simplified model of hydrated biological materials, from cartilaginous joints to the ocular tear film. However, the lubrication mechanisms of hydrogels remain poorly understood, partly due to their complex polymeric structure, which creates blurred interfaces during sliding that are challenging to study experimentally. In this study, we employ dissipative particle dynamics (DPD) to investigate the frictional behavior of a polymeric hydrogel network sliding against a solid wall in an explicit viscous solvent. This computational approach enables us to model hydrodynamic interactions and mesoscale polymer dynamics, capturing key aspects of hydrogel friction. Our simulations reveal that hydrogel friction is governed by the interplay between polymer relaxation and viscous shear, characterized by the Weissenberg number (Wi). At low Wi, friction coefficient remain nearly constant, dominated by polymer relaxation. However, at higher Wi, friction is dominated by viscous drag within a near-wall solvent layer, leading to a linear increase in friction coefficient with Wi. Furthermore, our results demonstrate an inverse relationship between the friction coefficient and the applied normal load, consistent with experimental observations. This work provides new insights into the fundamental tribological properties of hydrogels, shedding light on the micromechanics of hydrogel friction. Improving our understanding of hydrogel structure and dynamics under friction advances our knowledge of the mechanisms regulating biological lubrication in health and disease.
36 MATERIALS SCIENCE↗
Optimization of conical hydrostatic bearing for minimum friction.
Equations for the flow rate, load capacity, and friction torque for a conical hydrostatic bearing were developed. These equations were solved by a digital computer program to determine bearing configurations for minimum friction torque. Design curves are presented that show optimal bearing dimensions for minimum friction torque as a function of dimensionless flow rate for a range of dimensionless load capacity. Results are shown for both laminar and turbulent flow conditions. The results indicate that hydrostatic pocket friction is a significant portion of the total friction torque. However, the bearing dimensions for a minimum friction design are affected very little by inclusion of pocket friction in the analysis. For laminar flow the values of the outer-land radius ratio X3 and outer bearing radius ratio X4 did not change significantly with increasing friction factor. For turbulent flow, the outer bearing radius ratio X4 did not change with increasing friction factor; therefore the value determined for X4 in the laminar flow case is valid for all turbulent flows.
Nypan, L. J.↗
In-Flight Capability for Evaluating Skin-Friction Gages and Other Near-Wall Flow Sensors
An 8-in.-square boundary-layer sensor panel has been developed for in-flight evaluation of skin-friction gages and other near-wall flow sensors on the NASA Dryden Flight Research Center F-15B/Flight Test Fixture (FTF). Instrumentation on the sensor panel includes a boundary-layer rake, temperature sensors, static pressure taps, and a Preston tube. Space is also available for skin-friction gages or other near-wall flow sensors. Pretest analysis of previous F-15B/FTF flight data has identified flight conditions suitable for evaluating skin-friction gages. At subsonic Mach numbers, the boundary layer over the sensor panel closely approximates the two-dimensional (2D), law-of-the-wall turbulent boundary layer, and skin-friction estimates from the Preston tube and the rake (using the Clauser plot method) can be used to evaluate skin-friction gages. At supersonic Mach numbers, the boundary layer over the sensor panel becomes complex, and other means of measuring skin friction are needed to evaluate the accuracy of new skin-friction gages. Results from the flight test of a new rubber-damped skin-friction gage confirm that at subsonic Mach numbers, nearly 2D, law-of-the-wall turbulent boundary layers exist over the sensor panel. Sensor panel data also show that this new skin-friction gage prototype does not work in flight.
Bui, Trong T.↗
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↗
Tool For Friction Stir Tack Welding of Aluminum Alloys
A small friction-stir-welding tool has been developed for use in tack welding of aluminum-alloy workpieces. It is necessary to tack-weld the workpieces in order to hold them together during friction stir welding because (1) in operation, a full-size friction-stir-welding tool exerts a large force that tends to separate the workpieces and (2) clamping the workpieces is not sufficient to resist this force. It is possible to tack the pieces together by gas tungsten arc welding, but the process can be awkward and time-consuming and can cause sufficient damage to necessitate rework. Friction stir tack welding does not entail these disadvantages. In addition, friction stir tack welding can be accomplished by use of the same automated equipment (except for the welding tool) used in subsequent full friction stir welding. The tool for friction stir tack welding resembles the tool for full friction stir welding, but has a narrower shoulder and a shorter pin. The shorter pin generates a smaller workpiece-separating force so that clamping suffices to keep the workpieces together. This tool produces a continuous or intermittent partial-penetration tack weld. The tack weld is subsequently consumed by action of the larger tool used in full friction stir welding tool.
Bjorkman, Gerald W.↗
Damage Tolerance Assessment of Friction Pull Plug Welds in an Aluminum Alloy
Friction stir welding is a solid state welding process used in the fabrication of cryogenic propellant tanks. Self-reacting friction stir welding is one variation of the friction stir weld process being developed for manufacturing tanks. Friction pull plug welding is used to seal the exit hole that remains in a circumferential self-reacting friction stir weld. A friction plug weld placed in a self-reacting friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, 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 relating residual strength capability to flaw size in an aluminum alloy friction plug weld will be presented.
McGill, Preston↗
Development and Testing of a Friction-Based Post-Installable Sensor for Subsea Fiber-Optic Monitoring Systems
This paper presents the design and development of a friction-based coupling device for a fiber-optic monitoring system that can be deployed on existing subsea structures. This paper provides a summary of the design concept, prototype development, prototype performance testing, and design refinements of the device. The results of the laboratory testing of the first prototype performed at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) are included in this paper. Limitations of the initial design were identified and future design improvements were proposed. These new features will enhance the coupling of the device and improve the monitoring system measurement capabilities. A major challenge of a post-installed instrumentation monitoring system is to ensure adequate coupling between the instruments and the structure of interest for reliable measurements. Friction-based coupling devices have the potential to overcome coupling limitations caused by marine growth and soil contamination on subsea structures, flowlines or risers. The work described in this paper investigates the design of a friction-based coupling device (friction clamp), which is applicable for pipelines and structures that are suspended in the water column and those that are resting on the seabed. The monitoring elements consist of fiber-optic sensors that are bonded to a metal clamshell with a high-friction coating. The friction clamp has a single hinge design to facilitate the operation of the clamp and dual rows of opposing fasteners to distribute the clamping force on the structure. The friction clamp can be installed by divers in shallow depths or by remotely operated vehicles in deep-water applications. NASA-JSC was involved in the selection and testing of the friction coating, and in the design and testing of the prototype clamp device. Four-inch diameter and eight-inch diameter sub-scale friction clamp prototypes were built and tested to evaluate the strain measuring capabilities of the design under different loading scenarios. The testing revealed some limitations of the initial design concept, and subsequent refinements were explored to improve the measurement performance of the system. This study was part of a collaboration between NASA-JSC and Astro Technology, Inc. within a study called Clear Gulf. The primary objective of the Clear Gulf study is to develop advanced instrumentation technologies that will improve operational safety and reduce the risk of hydrocarbon spillage. NASA provided unique insights, expansive test facilities, and technical expertise to advance these technologies that would benefit the environment, the public, and commercial industries.
Bentley, Nicole↗
Development and Testing of a Friction-Based Post-Installable Sensor for Subsea Fiber-Optic Monitoring System
This paper presents the design and development of a friction-based coupling device for a fiber-optic monitoring system that can be deployed on existing subsea structures. This paper provides a summary of the design concept, prototype development, prototype performance testing, and design refinements of the device. The results of the laboratory testing of the first prototype performed at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) are included in this paper. Limitations of the initial design were identified and future design improvements were proposed. These new features will enhance the coupling of the device and improve the monitoring system measurement capabilities. A major challenge of a post-installed instrumentation monitoring system is to ensure adequate coupling between the instruments and the structure of interest for reliable measurements. Friction-based coupling devices have the potential to overcome coupling limitations caused by marine growth and soil contamination on subsea structures, flowlines or risers. The work described in this paper investigates the design of a friction-based coupling device (friction clamp), which is applicable for pipelines and structures that are suspended in the water column and those that are resting on the seabed. The monitoring elements consist of fiber-optic sensors that are bonded to a metal clamshell with a high-friction coating. The friction clamp has a single hinge design to facilitate the operation of the clamp and dual rows of opposing fasteners to distribute the clamping force on the structure. The friction clamp can be installed by divers in shallow depths or by remotely operated vehicles in deep-water applications. NASA-JSC was involved in the selection and testing of the friction coating, and in the design and testing of the prototype clamp device. Four-inch diameter and eight-inch diameter sub-scale friction clamp prototypes were built and tested to evaluate the strain measuring capabilities of the design under different loading scenarios. The testing revealed some limitations of the initial design concept, and subsequent refinements were explored to improve the measurement performance of the system. This study was part of a collaboration between NASA-JSC and Astro Technology, Inc. within a study called Clear Gulf. The primary objective of the Clear Gulf study is to develop advanced instrumentation technologies that will improve operational safety and reduce the risk of hydrocarbon spillage. NASA provided unique insights, expansive test facilities, and technical expertise to advance these technologies that would benefit the environment, the public, and commercial industries.
Bentley, Nicole L.↗
Development and Testing of a Friction-Based Post-Installable Fiber-Optic Monitoring System for Subsea Applications
This paper presents the design and development of a friction-based coupling device for a fiber-optic monitoring system capable of measuring pressure, strain, and temperature that can be deployed on existing subsea structures. A summary is provided of the design concept, prototype development, prototype performance testing, and subsequent design refinements of the device. The results of laboratory testing of the first prototype performed at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) are also included. Limitations of the initial concept were identified during testing and future design improvements were proposed and later implemented. These new features enhance the coupling of the sensor device and improve the monitoring system measurement capabilities. A major challenge of a post-installed instrumentation monitoring system is to ensure adequate coupling between the instruments and the structure of interest for reliable measurements. Friction-based devices have the potential to overcome coupling limitations caused by marine growth and soil contamination on flowlines, risers, and other subsea structures. The work described in this paper investigates the design and test of a friction-based coupling device (herein referred to as a friction clamp) which is suitable for pipelines and structures that are suspended in the water column as well as for those that are resting on the seabed. The monitoring elements consist of fiberoptic sensors that are bonded to a stainless steel clamshell assembly with a high-friction surface coating. The friction clamp incorporates a single hinge design to facilitate installation of the clamp and dual rows of opposing fasteners to distribute the clamping force along the structure. The friction clamp can be modified to be installed by commercial divers in shallow depths or by remotely operated vehicles in deep-water applications. NASA-JSC was involved in the selection and testing of the friction coating, and in the design and testing of the prototype clamp device. Four-inch diameter and eight-inch diameter sub-scale friction clamp prototypes were built and tested to evaluate the strain measuring capabilities of the design under different loading scenarios. The testing revealed some limitations of the initial design concept, and subsequent refinements were explored to improve the measurement performance of the system. This study was part of a collaboration between NASA-JSC and Astro Technology Inc. within a study called Clear Gulf. The primary objective of the Clear Gulf study is to develop advanced instrumentation technologies that will improve operational safety and reduce the risk of hydrocarbon spillage. NASA provided unique insights, expansive test facilities, and technical expertise to advance technologies that will benefit the environment, the public, and commercial industries.
Bentley, Nicole L.↗
Gimbal Bearing Friction in the SLS Core Stage Thrust Vector Control System
The Space Launch System (SLS) Core Stage Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators that vector the four Shuttle heritage RS-25 engines about a Shuttle heritage gimbal block/bearing. The MSFC Controls community has long regarded gimbal friction to be a negligible effect on the overall control of gimbaled RS-25 engines. This is corroborated by Space Shuttle test and flight data that does not appear to show degraded effects, nor limit cycling at the end of the shuttle flight. For this reason, friction was not expected to be a driving factor of performance and control of the reused RS-25 engines aboard the SLS. However, after test data showed a large shift in frequency behavior and a highly damped step-response in the time series, there was further investigation into what could have caused this behavior. Heritage friction models used in previous gimbal and ball bearings were evaluated such as Coulomb, Dahl and LuGre, but the single degree of freedom friction models alone were not enough to explain the behavior and shifts seen in the test data. This paper presents the additional findings and modeling efforts regarding friction on the RS-25 engines. Using the Two Actuator Operational Simulation (TAOS), the difference from modeling separate friction degrees of freedom to coupled degrees of freedom was investigated to deduce the effects of one axis’s movement on the other. Next, due to the vibration environment, a modified LuGre model has been proposed that adds an additional term to decrease the friction coefficient at low engine velocity amplitudes. Lastly, the addition of the stiffness in each half of the gimbal bearing has increased modeling fidelity by also adding the effect on the gimbal bearing bending in compliance to both the friction torque on the surface of the gimbal bearing and the actuator force that is forcing the engine in a specified direction. Through these effects, the time and frequency domain behavior seen in test can be characterized accurately.
Friction↗
Gimbal Bearing Friction in the SLS Core Stage Thrust Vector Control System
The Space Launch System (SLS) Core Stage Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators that vector the four Shuttle heritage RS-25 engines about a Shuttle heritage gimbal block/bearing. The MSFC Controls community has long regarded gimbal friction to be a negligible effect on the overall control of gimbaled RS-25 engines. This is corroborated by Space Shuttle test and flight data that does not appear to show degraded effects, nor limit cycling at the end of the shuttle flight. For this reason, friction was not expected to be a driving factor of performance and control of the reused RS-25 engines aboard the SLS. However, after test data showed a large shift in frequency behavior and a highly damped step-response in the time series, there was further investigation into what could have caused this behavior. Heritage friction models used in previous gimbal and ball bearings were evaluated such as Coulomb, Dahl and LuGre, but the single degree of freedom friction models alone were not enough to explain the behavior and shifts seen in the test data. This paper presents the additional findings and modeling efforts regarding friction on the RS-25 engines. Using the Two Actuator Operational Simulation (TAOS), the difference from modeling separate friction degrees of freedom to coupled degrees of freedom was investigated to deduce the effects of one axis’s movement on the other. Next, due to the vibration environment, a modified LuGre model has been proposed that adds an additional term to decrease the friction coefficient at low engine velocity amplitudes. Lastly, the addition of the stiffness in each half of the gimbal bearing has increased modeling fidelity by also adding the effect on the gimbal bearing bending in compliance to both the friction torque on the surface of the gimbal bearing and the actuator force that is forcing the engine in a specified direction. Through these effects, the time and frequency domain behavior seen in test can be characterized accurately.
Friction↗
Current status of Joint FAA/NASA Runway Friction Program
Tests with specially instrumented NASA B-737 and FAA B-727 aircraft together with several different ground friction measuring devices have been conducted for a variety of runway surface types and wetness conditions. This effort is part of the Joint FAA/NASA Aircraft Ground Vehicle Runway Friction Program aimed at obaining a better understanding of aircraft ground handling performance under adverse weather conditions and defining relationships between aircraft and ground vehicle tire friction measurements. Aircraft braking performance on dry, wet, snow-, and ice-covered runway conditions is discussed together with ground vehicle friction data obtained under similar runway conditions. For the wet, compacted snow- and ice-covered runway conditions, the relationship between ground vehicles and aircraft friction data is identified. The influence of major test parameters on friction measurements such as speed, test tire characteristics, and surface contaminant type are discussed. The test results indicate that use of properly maintained and calibrated ground vehicles for monitoring runway friction conditions should be encouraged particularly under adverse weather conditions. The current status of the runway friction program is summarized and future test plans are identified.
Yager, Thomas J.↗
Friction-factor characteristics for narrow channels with honeycomb surfaces
The experimental determination of friction-factors for the flow of air in a narrow channel lined with various honeycomb geometries has been carried out. Test results show that, generally, the friction-factor is nearly constant or slightly decreases as the Reynolds number increases, a characteristic common to turbulent flow in pipes. However, in some test geometries this trend is remarkably different. The friction factor dramatically drops and then rises as the Reynolds number increases. This phenomenon can be characterized as a 'friction-factor jump'. Further investigations of the acoustic spectrum and friction-factor measurements for a broad range of Reynolds numbers indicate that the 'friction-factor jump' phenomenon is accompanied by an onset of a normal mode resonance excited coherent flow fluctuation structure, which occurs at Reynolds number of the order of 10,000. The purpose of this paper is to explain the friction-factor-jump phenomenon and friction-factor characteristics.
Ha, T. W.↗