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36 records · Page 2

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

42 ENGINEERING↗

NASA NTRS1972

State-of-technology for joining TD-NiCr sheet.

At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding (EBW), gas-tungsten arc welding (GTAW), diffusion welding (DFW), resistance spot welding (RSW), resistance seam welding (RSEW), and brazing. Roll welding (RW) and explosion welding (EXW) have not been developed to the point where they can be used to make sound welds in TD-NiCr. Joining work that has previously been done on TD-NiCr by various organizations, both privately supported and under Air Force and NASA contracts, is described in this summary. Current work is also described that is being done at General Dynamics/Convair (under NASA contract) and at NASA/Lewis to develop and evaluate DFW, RSW, RSEW, and brazing. Preliminary comparisons of joining processes are made for typical applications. A brief description of the manufacture of TD-NiCr sheet by a recently standardized process (under NASA contract) also is given.

Holko, K. H.↗

NASA NTRS2000

Test Cases for a Rectangular Supercritical Wing Undergoing Pitching Oscillations

Steady and unsteady measured pressures for a Rectangular Supercritical Wing (RSW) undergoing pitching oscillations have been presented. From the several hundred compiled data points, 27 static and 36 pitching oscillation cases have been proposed for computational Test Cases to illustrate the trends with Mach number, reduced frequency, and angle of attack. The wing was designed to be a simple configuration for Computational Fluid Dynamics (CFD) comparisons. The wing had an unswept rectangular planform plus a tip of revolution, a panel aspect ratio of 2.0, a twelve per cent thick supercritical airfoil section, and no twist. The model was tested over a wide range of Mach numbers, from 0.27 to 0.90, corresponding to low subsonic flows up to strong transonic flows. The higher Mach numbers are well beyond the design Mach number such as might be required for flutter verification beyond cruise conditions. The pitching oscillations covered a broad range of reduced frequencies. Some early calculations for this wing are given for lifting pressure as calculated from a linear lifting surface program and from a transonic small perturbation program. The unsteady results were given primarily for a mild transonic condition at M = 0.70. For these cases the agreement with the data was only fair, possibly resulting from the omission of viscous effects. Supercritical airfoil sections are known to be sensitive to viscous effects (for example, one case cited). Calculations using a higher level code with the full potential equations have been presented for one of the same cases, and with the Euler equations. The agreement around the leading edge was improved, but overall the agreement was not completely satisfactory. Typically for low-aspect-ratio rectangular wings, transonic shock waves on the wing tend to sweep forward from root to tip such that there are strong three-dimensional effects. It might also be noted that for most of the test, the model was tested with free transition, but a few points were taken with an added transition strip for comparison. Some unpublished results of a rigid wing of the same airfoil and planform that was tested on the pitch and plunge apparatus mount system (PAPA) showed effects of the lower surface transition Strip on flutter at the lower subsonic Mach numbers. Significant effects of a transition strip were also obtained on a wing with a thicker supercritical section on the PAPA mount system. Both of these flutter tests on the PAPA resulted in very low reduced frequencies that may be a factor in this influence of the transition strip. However, these results indicate that correlation studies for RSW may require some attention to the estimation of transition location to accurately treat viscous effects. In this report several Test Cases are selected to illustrate trends for a variety of different conditions with emphasis on transonic flow effects. An overview of the model and tests is given and the standard formulary for these data is listed. Sample data points are presented in both tabular and graphical form. A complete tabulation and plotting of all the Test Cases is given. Only the static pressures and the real and imaginary parts of the first harmonic of the unsteady pressures are available. All the data for the test are available in electronic file form. The Test Cases are also available as separate electronic files.

Bennett, Robert M.↗

NASA NTRS2013

Lessons Learned in the Selection and Development of Test Cases for the Aeroelastic Prediction Workshop: Rectangular Supercritical Wing

The Aeroelastic Prediction Workshop brought together an international community of computational fluid dynamicists as a step in defining the state of the art in computational aeroelasticity. The Rectangular Supercritical Wing (RSW) was chosen as the first configuration to study due to its geometric simplicity, perceived simple flow field at transonic conditions and availability of an experimental data set containing forced oscillation response data. Six teams performed analyses of the RSW; they used Reynolds-Averaged Navier-Stokes flow solvers exercised assuming that the wing had a rigid structure. Both steady-state and forced oscillation computations were performed by each team. The results of these calculations were compared with each other and with the experimental data. The steady-state results from the computations capture many of the flow features of a classical supercritical airfoil pressure distribution. The most dominant feature of the oscillatory results is the upper surface shock dynamics. Substantial variations were observed among the computational solutions as well as differences relative to the experimental data. Contributing issues to these differences include substantial wind tunnel wall effects and diverse choices in the analysis parameters.

Heeg, Jennifer↗

DOE OSTI2018

Suggestion of an Indicator to Evaluate Material Deposition in Resistance Spot Welding: Weld–Surface Interaction Index

Resistance spot welding (RSW) is still leading joining process in the automotive industry due to the simplicity and speed of the process. On the other hand, galvanized steel sheets provide improvement in corrosion resistance of the auto body. Material deposition has an influence on the corrosion resistance and weld strength; however, in the literature very little effort has been made to identify any weld–surface interaction numerically. In this study, a numerical approach called “Weld–Surface Interaction Index” (I{sub WSI}) has been introduced to investigate the effect of material deposition on the corrosion sensitivity of the welding zone and its periphery. A systematic investigation was carried out to better understand the effects of an electrode cap–galvanized steel sheet interface on the corrosion resistance of spot-welded steel. The chemical composition of DP600 steel sheet and Z-Trode electrode cap was analyzed by using a spectrometer. The specimens were then joined by using same caps up to 1200 welds. SEM–EDS analysis was also performed on the chosen specimens to determine the weight percentages (wt.%) of Fe, Zn and Cu. EDS analysis results and coefficient of variation wt.% of Fe, Zn and Cu were used to compose I{sub WSI} formula. In the proposed formula, wt.% of Zn represented resistivity of the cover to corrosion, while wt.% of Fe represents the vulnerability.

36 MATERIALS SCIENCE↗

DOE OSTI2024

MaterialsMap: A CALPHAD-based tool to design composition pathways through feasibility map for desired dissimilar materials, demonstrated with resistance spot welding joining of Ag-Al-Cu

Assembly of dissimilar metals can be achieved by different methods, for example, casting, welding, and additive manufacturing (AM). However, undesired phases formed in liquid-phase assembling processes due to solute segregation during solidification diminish mechanical and other properties of the processed parts. In the present work, an open-source software named MaterialsMap, has been developed based on the CALculation of Phase Diagrams (CALPHAD) approach. The primary objective of MaterialsMap is to facilitate the design of an optimal composition pathway for assembling dissimilar alloys with liquid-phases based on the formation of desired and undesired phases along the pathway. In MaterialsMap, equilibrium thermodynamic calculations are used to predict equilibrium phases formed at slow cooling rate, while Scheil-Gulliver simulations are employed to predict non-equilibrium phases formed during rapid cooling. Additionally, by combining these two simulations, MaterialsMap offers a thorough guide for understanding phase formation in various manufacturing processes, assisting users in making informed decisions during material selection and production. As a demonstration of this approach, a compositional pathway was designed from pure Al to pure Cu through Ag using MaterialsMap. The design was experimentally verified using resistance spot welding (RSW).

36 MATERIALS SCIENCE↗

DOE OSTI2022

Physics-informed machine learning assisted uncertainty quantification for the corrosion of dissimilar material joints

Jointing techniques like the Self-Piercing Riveting (SPR), Resistance Spot Welding (RSW) and Rivet-Weld (RW) joints are used for mass production of dissimilar material joints due to their high performance, short cycle time, and adaptability. However, the service life and safety usage of these joints can be largely impacted by the galvanic corrosion due to the difference in equilibrium potentials between the metals with the presence of electrolyte. Here, in this paper, we focus on Al-Fe galvanic corrosion and develop physics-informed machine learning based surrogate model for statistical corrosion analysis, which enables the reliability analysis of dissimilar material joints under corrosion environment. In this study, a physics-based finite element (FE) corrosion model has been developed to simulate the galvanic corrosion between a Fe cathode and an Al anode. Geometric and environmental factors including crevice gap, roughness of anode, conductivity, and the temperature of the electrolyte are investigated. Further, a thorough Uncertainty Quantification (UQ) analysis is conducted for the overall corrosion behavior of the Fe-Al joints. It is found that the electrolyte conductivity has the largest effects on the material loss and needs to be managed closely for better corrosion control. This will help in designing and manufacturing joints with improved corrosion performance.

42 ENGINEERING↗

NASA NTRS1972

State-of-technology for joining TD-NiCr sheet

At the current state-of-technology there are many joining processes that can be used to make sound welds in TD-NiCr sheet. Some of these that are described in this report are electron beam welding, gas-tungsten arc welding, diffusion welding, resistance spot welding, resistance seam welding, and brazing. The strengths of the welds made by the various processes show considerable variation, especially at elevated temperatures. Most of the fusion welding processes tend to give weak welds at elevated temperatures (with the exception of fusion-type resistance spotwelds). However, solid-state welds have been made with parent metal properties. The process used for a specific application will be dictated by the specific joint requirements. In highly stressed joints at elevated temperatures, one of the solid-state processes, such as DFW, RSW (solid-state or fusion), and RSEW, offer the most promise.

Holko, K. H.↗

NASA NTRS1992

Low cost, SPF aluminum cryogenic tank structure for ALS

Past production work has shown that cryogenic tank structure for the Shuttle Booster Rockets and the Titan system have very high life cycle costs for the fuel tank structure. The tanks are machined stiffener-skin combination that are subsequently formed into the required contour after machining. The material scrap rate for these configurations are usually high, and the loss of a tank panel due to forming or heat treatment problems is very costly. The idea of reducing the amount of scrap material and scrapped structural members has prompted the introduction of built-up structure for cryogenic tanks to be explored on the ALS program. A build-up structure approach that has shown improvements in life cycle cost over the conventional built-up approach is the use of superplastically formed (SPF) stiffened panels (reducing the overall part count and weight for the tank) resistance spot welded (RSW) to outer tank skin material. The stiffeners provide for general stability of the tank, while the skin material provides hoop direction continuity for the loads.

Anton, Claire E.↗

NASA NTRS1999

Hot Gas Testing Results of Stagnant Volume Filling Through a Back-Filled RSRM Nozzle Joint

Silicone rubber is back-filled into RSW nozzle joints after assembly. A possible artifact of this process is the formation of small pathways through this filter leading to sensitive sealing materials within the joint. At motor ignition, hot gases fill the stagnant volumes within the joint through this path. A series of 14 test has been completed studying this scenario and providing anchoring data for thermal/flow models. Parameters such as gas path cross section, gas path length, gas path materials, fill volume size, and post path gas spreading prior to unpingement on seal material, have been investigated. Tests were accomplished using geometry similar to RSRM nozzle joint 4 with attached volumes replicating the free volume and flow friction in the actual hardware. The test hardware simulated 8 inches of the full-scale circumference. Testing has pointed to changes required in model boundary condition assumptions and gas dynamics corrections for gas paths of this size and geometry. Areas ,where this date has provided improvement in analysis models will be covered as well as model inadequacies that require separate specialized efforts. Questions remaining after this testing and a possible direction for future testing will be suggested.

Prince, Andrew S.↗

NASA NTRS2000

CLAES Product Improvement by Use of the GSFC Data Assimilation System (DAS)

This report presents the Cryogenic Limb Array Etalon Spectrometer (CLAES) product improvement by use of the GSFC Data Assimilation System (DAS). The first task is to plug line of sight gradients derived from the CTM for 2/20/92 into the forward model of our retrieval software (RSW) in order to assess the impact on the retrieved quantities. The reporting period covers 12 May 2000 - 21 December 2000.

Kumer, J. B.↗

NASA NTRS1997

Earth Radiation Budget Experiment (ERBE) Data Sets for Global Environment and Climate Change Studies

For a number of years there has been considerable interest in the earth's radiation budget (ERB) or energy balance, and entails making the best measurements possible of absorbed solar radiation, reflected shortwave radiation (RSW), thermal outgoing longwave radiation (OLR), and net radiation. ERB data are fundamental to the development of realistic climate models and studying natural and anthropogenic perturbations of the climate. Much of the interest and investigations in the earth's energy balance predated the age of earth-orbiting satellites (Hunt et al., 1986). Beginning in the mid 1960's earth-orbiting satellites began to play an important role in making measurements of the earth's radiation flux although much effort had gone into measuring ERB parameters prior to 1960 (House et al., 1986). Beginning in 1974 and extending until the present time, three different satellite experiments (not all operating at the same time) have been making radiation budget measurements almost continually in time. Two of the experiments were totally dedicated to making radiation budget measurements of the earth, and the other experiment flown on NOAA sun-synchronous AVHRR weather satellites produced radiation budget parameters as a by-product. The heat budget data from the AVHRR satellites began collecting data in June 1974 and have operated almost continuously for 23 years producing valuable data for long term climate monitoring.

Bess, T. Dale↗

NASA NTRS2005

Using a Web Browser for Environmental and Climate Change Studies

A new web browser for viewing and manipulating meteorological data sets is located on a web server at NASA, Langley Research Center. The browser uses a live access server (LAS) developed by the Thermal Modeling and Analysis Project at NOAA's Pacific Marine Environmental Laboratory. LAS allows researchers to interact directly with the data to view, select, and subset the data in terms of location (latitude, longitude) and time such as day, month, or year. In addition, LAS can compare two data sets and can perform averages and variances, LAS is used here to show how it functions as an internet/web browser for use by the scientific and educational community. In particular its versatility in displaying and manipulating data sets of atmospheric measurements in the earth's radiation budget (ERB) or energy balance, which includes measurements of absorbed solar radiation, reflected shortwave radiation (RSW), thermal outgoing longwave radiation (OLR), and net radiation is demonstrated. These measurements are from the Clouds and the Earth's Radiant Energy System (CERES) experiment and the surface radiation budget (SRB) experiment.

Bess, T. Dale↗

NASA NTRS2002

Using a Web Browser for Environmental and Climate Change Studies

A new web browser for viewing and manipulating meteorological data sets is located on a web server at NASA, Langley Research Center. The browser uses a live access server (LAS) developed by the Thermal Modeling and Analysis Project at NOAA's Pacific Marine Environmental Laboratory. LAS allows researchers to interact directly with the data to view, select, and subset the data in terms of location (latitude, longitude) and time such as day, month, or year. In addition, LAS can compare two data sets and can perform averages and variances, LAS is used here to show how it functions as an internet/web browser for use by the scientific and educational community. In particular its versatility in displaying and manipulating data sets of atmospheric measurements in the earth s radiation budget (ERB) or energy balance, which includes measurements of absorbed solar radiation, reflected shortwave radiation (RSW), thermal outgoing longwave radiation (OLR), and net radiation is demonstrated. These measurements are from the Clouds and the Earth s Radiant Energy System (CERES) experiment and the surface radiation budget (SRB) experiment.

Bess, T. Dale↗

DOE OSTI2013

MODELING OF HIGH SPEED FRICTION STIR SPOT WELDING USING A LAGRANGIAN FINITE ELEMENT APPROACH

Friction stir spot welding (FSSW) has been shown to be capable of joining steels of very high strength, while also being very flexible in terms of controlling the heat of welding and the resulting microstructure of the joint. This makes FSSW a potential alternative to resistance spot welding (RSW) if tool life is sufficiently high, and if machine spindle loads are sufficiently low so that the process can be implemented on an industrial robot. Robots for spot welding can typically sustain vertical loads of about 8kN, but FSSW at tool speeds of less than 3000 rpm cause loads that are too high, in the range of 11-14 kN. Therefore, in the current work tool speeds of 3000 rpm and higher were employed, in order to generate heat more quickly and to reduce welding loads to acceptable levels. The FSSW process was modeled using a finite element approach with the Forge® software package. An updated Lagrangian scheme with explicit time integration was employed to model the flow of the sheet material, subjected to boundary conditions of a rotating tool and a fixed backing plate [3]. The modeling approach can be described as two-dimensional, axisymmetric, but with an aspect of three dimensions in terms of thermal boundary conditions. Material flow was calculated from a velocity field which was two dimensional, but heat generated by friction was computed using a virtual rotational velocity component from the tool surface. An isotropic, viscoplastic Norton-Hoff law was used to model the evolution of material flow stress as a function of strain, strain rate, and temperature. The model predicted welding temperatures and the movement of the joint interface with reasonable accuracy for the welding of a dual phase 980 steel.

Advanced High strength steel↗

DOE OSTI2012

Alternative cooling resource for removing the residual heat of reactor

The Recirculated Cooling Water (RCW) system of a Candu reactor is a closed cooling system which delivers demineralized water to coolers and components in the Service Building, the Reactor Building, and the Turbine Building and the recirculated cooling water is designed to be cooled by the Raw Service Water (RSW). During the period of scheduled outage, the RCW system provides cooling water to the heat exchangers of the Shutdown Cooling System (SDCS) in order to remove the residual heat of the reactor, so the RCW heat exchangers have to operate at all times. This makes it very hard to replace the inlet and outlet valves of the RCW heat exchangers because the replacement work requires the isolation of the RCW. A task force was formed to prepare a plan to substitute the recirculated water with the chilled water system in order to cool the SDCS heat exchangers. A verification test conducted in 2007 proved that alternative cooling was possible for the removal of the residual heat of the reactor and in 2008 the replacement of inlet and outlet valves of the RCW heat exchangers for both Wolsong unit 3 and 4 were successfully completed. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Next Gen High Efficiency Boosted Engine Development

This work represents an advanced engineering research project partially funded by the U.S. Department of Energy (DOE). Ford Motor Company, FEV North America, and Oak Ridge National Laboratory collaborated to develop a next generation boosted spark ignited engine concept. The project goals, specified by the DOE, were 23% improved fuel economy and 15% reduced weight relative to a 2015 or newer light-duty vehicle. The fuel economy goal was achieved by designing an engine incorporating high geometric compression ratio, high dilution tolerance, low pumping work, and low friction. The increased tendency for knock with high compression ratio was addressed using early intake valve closing (EIVC), cooled exhaust gas recirculation (EGR), an active pre-chamber ignition system, and careful management of the fresh charge temperature. Engine weight reduction measures were implemented throughout the engine system making use of composite materials, advanced manufacturing techniques, and architectural choices. This report outlines the analytical, design, fabrication, and test work conducted for the duration of the project. The combustion system stability, EGR tolerance, and knock resistance were validated on a single cylinder engine. An inline six-cylinder engine was then designed targeting application in the Ford F150. Multi-cylinder engines were produced and tested achieving the target vehicle fuel economy improvement of 23% assessed using measured engine fuel consumption combined with a vehicle drive cycle simulation. Actions were identified and designs were demonstrated to achieve the 15% weight reduction target. This project included items covering a range of technology readiness levels. Some of the technologies explored are production ready, while others were investigated to understand the limitations for what can be achieved in a stoichiometric, gasoline-fueled, spark-ignited internal combustion engine.

42 ENGINEERING↗