Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “friction”

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

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

An Alternative Frictional Boundary Condition for Computational Fluid Dynamics Simulation of Friction Stir Welding

For better application of numerical simulation in optimization and design of friction stir welding (FSW), this paper presents a new frictional boundary condition at the tool/workpiece interface for computational fluid dynamics (CFD) modeling of FSW. The proposed boundary condition is based on an implementation of the Coulomb friction model. Using the new boundary condition, the CFD simulation yields non-uniform distribution of contact state over the tool/workpiece interface, as validated by the experimental weld macrostructure. It is found that interfacial sticking state is present over large area at the tool-workpiece interface, while significant interfacial sliding occurs at the shoulder periphery, the lower part of pin side, and the periphery of pin bottom. Due to the interfacial sticking, a rotating flow zone is found under the shoulder, in which fast circular motion occurs. The diameter of the rotating flow zone is smaller than the shoulder diameter, which is attributed to the presence of the interfacial sliding at the shoulder periphery. For the simulated welding condition, the heat generation due to friction and plastic deformation makes up 54.4 and 45.6% of the total heat generation rate, respectively. In conclusion, the simulated temperature field is validated by the good agreement to the experimental measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Investigation of Interfacial Layer for Friction Stir Scribe Welded Aluminum to Steel Joints

Friction stir scribe (FSS) welding as a recent derivative of friction stir welding has successfully fabricated a linear joint between automotive Al and steel sheets. However, there is a lack of understanding on its bonding mechanism. In this paper, the microstructures and phases at the bonding interface of FSS welded Al to ultra-high strength steel joints were studied using scanning electron microscopy and transmission electron microscopy. Based on the microstructural analysis, it is found that both mechanical and chemical bonding occurred simultaneously, and the energy-dispersive X-ray spectroscopy revealed that a thin intermetallic compound (IMC) layer was formed at the interface. Owing to the varied material flow and heat generation, the IMC layer thickness gradually decreased from the advancing side to the retreating side, and two IMCs (i.e. Fe2Al5 and Fe4Al13) were confirmed in different weld regions using diffraction pattern (or 1D fast Fourier transform pattern). Also, a Fe/Al solid solution was noticed in the IMC layer, and several Al fringes were found in the Fe-rich side in the scribe stir zone.

friction stir scribe welding, interfacial layer, i↗
DOE OSTI2017

Friction consolidation of gas-atomized Fe−Si powders for soft magnetic applications

Soft magnetic materials are often limited in scalability due to conventional processes that do not retain beneficial microstructures, and their associated physical properties, during densification. In this work, friction consolidation (FC) has been studied to fabricate Fe−Si soft magnetic materials from gas-atomized powder precursors. Fe−Si powder is consolidated using variable pressure and tool rotation speed in an effort to evaluate this unique densification approach for potential improvements in magnetic properties. FC, due to the high shear deformation involved, is shown to result in uniform gradual grain structure refinement across the consolidated workpiece from the center nearest the tool to the edge. Magnetic properties along different orientations indicate little, if any, textural orientation in the refined grain structure. The effect of annealing on the magnetic properties is evaluated and shown to decrease coercivity. FC processing was able to retain the magnetization of the original gas-atomized powders but further process optimization is needed to reach the optimal coercivity for the soft magnetic materials applications. - Highlights: •Friction stir processing was utilized to consolidate Fe−Si soft magnetic powders. •The resultant microstructure and magnetic properties were correlated to the processing conditions. •Friction consolidation refined the grain size of the materials by ~ 40%. •Annealing successfully reduced the coercivity induced by the stress during processing. •The results shine light on the possible scaling up of nanostructured materials.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Enabling Dissimilar Material Joining Using Friction Stir Scribe Technology

One challenge in adapting welding processes to dissimilar material joining is the diversity of melting temperatures of the different materials. Although the use of mechanical fasteners and adhesives have mostly paved the way for near-term implementation of dissimilar material systems, these processes only accentuate the need for low-cost welding processes capable of joining dissimilar material components regardless of alloy, properties, or melting temperature. Friction stir scribe technology was developed to overcome the challenges of joining dissimilar material components where melting temperatures vary greatly, and properties and/or chemistry are not compatible with more traditional welding processes. Although the friction stir scribe process is capable of joining dissimilar metals and metal/polymer systems, a more detailed evaluation of several aluminum/steel joints is presented herein to demonstrate the ability to both chemically and mechanically join dissimilar materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A kinetic model of friction in strongly coupled strongly magnetized plasmas

Plasmas that are strongly magnetized in the sense that the gyrofrequency exceeds the plasma frequency exhibit novel transport properties that are not well understood. As a representative example, we compute the friction force acting on a massive test charge moving through a strongly coupled and strongly magnetized one-component plasma using a generalized Boltzmann kinetic theory. Recent works studying the weakly coupled regime have shown that strong magnetization leads to a transverse component of the friction force that is perpendicular to both the Lorentz force and velocity of the test charge, in addition to the stopping power component aligned antiparallel to the velocity. Recent molecular dynamics simulations have also shown that strong Coulomb coupling in addition to strong magnetization gives rise to a third component of the friction force in the direction of the Lorentz force. Here, we show that the generalized Boltzmann kinetic theory captures these effects and generally agrees well with the molecular dynamics simulations over a broad range of Coulomb coupling and magnetization strength regimes. The theory is also used to show that the “gyro” component of the friction in the direction of the Lorentz force arises due to asymmetries associated with gyromotion during short-range collisions. Computing the average motion of the test charge through the background plasma, the transverse force is found to strongly influence the trajectory by changing the gyroradius and the gyrofriction force is found to slightly change the gyrofrequency of the test charge resulting in a phase shift.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1974

Friction and friction-generated temperature at a polymer-metal interface

Results of friction and thermal tests of molded polyimide and pyrrone polymers are presented. The coefficient of sliding friction up to surface velocities of 2 m/sec and the coefficient of thermal expansion from 300 to 500 K were measured. An apparatus was constructed to measure simultaneously the coefficient of sliding friction and the friction-generated temperature. Measurements were made at a nominal pressure-velocity product of 0.25 MN/msec and at temperatures between 300 and 500 K.

Price, H. L.↗
NASA NTRS1988

Aircraft and ground vehicle friction correlation test results obtained under winter runway conditions during joint FAA/NASA Runway Friction Program

Aircraft and ground vehicle friction data collected during the Joint FAA/NASA Runway Friction Program under winter runway conditions are discussed and test results are summarized. The relationship between the different ground vehicle friction measurements obtained on compacted snow- and ice-covered conditions is defined together with the correlation to aircraft tire friction performance under similar runway conditions.

Yager, Thomas J.↗
NASA NTRS2002

The Effect of Friction on Penetration in Friction Stir Welding

"Friction stir butt welding," as it was originally termed by Wayne Thomas and Christopher Dawes, in the early 1990s, but now commonly called "friction stir welding," has made great progress as a new welding technique. Commercially, friction stir welding (FSW) is finding many applications. Marine Aluminum of Norway is using the process for welding 20-meter aluminum sheets for ferry construction. Japan is using the technique in development work on bullet trains. Sapa of Sweden utilizes FSW in the landing of refrigeration units for cargo ships. In the United States, Boeing is using the technique in the production of Delta rockets. Eclipse Aviation Corporation plans to use FSW to produce a business jet available in August, 2003. Marshall Space Flight Center has been investigating the use of FSW for assembly of the Shuttle's external fuel tank since the late 1990s and hopes to have the process in use by the summer of 2002. In FSW, a cylindrical pin tool of hardened steel, is rotated and plunged into the abutting edges of the parts to be joined. The tool is plunged into the weldment to within about .050 in of the bottom to assure full penetration. As the tool moves along the joint, the tool shoulder helps produce frictional heating, causing the material to plasticize. The metal of the two abutting plates flows from the front of the tool to the back where it cools and coalesces to form a weld in the solid phase.

Steve Rapp↗
DOE OSTI2018

On the Similarity of Deformation Mechanisms During Friction Stir Welding and Sliding Friction of the AA5056 Alloy

A comparative investigation of the structure of an aluminum-manganese alloy is performed after its friction stir welding and sliding friction. Using the methods of optical and electron microscopy, it is shown that during friction identical ultrafine-grained structures are formed in the weld nugget and in the surface layer, in which the grains measure ~ 5 μm irrespective of the initial grain size of the alloy. An assumption is made that the microstructure during both processes under study is formed by the mechanism of rotational plasticity.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Highly Branched Polyethylenes as Lubricant Viscosity and Friction Modifiers

A series of highly branched polyethylenes (BPE) were prepared and used in a Group I base oil as potential viscosity and friction modifiers. The lubricating performance of these BPEs supports the expected dual functionality. Changes in polarity, topology, and molecular weight of the BPEs showed significant effects on the lubricants’ performance, which provide scientific insights for polymer design in future lubricant development.

Branchedpolyethylene↗
DOE OSTI2016

Joining Dissimilar Materials Using Friction Stir Scribe Technique

Development of a robust and cost-effective method of joining dissimilar materials could provide a critical pathway to enable widespread use of multi-material designs and components in mainstream industrial applications. The use of multi-material components such as steel-aluminum and aluminum-polymer would allow design engineers to optimize material utilization based on service requirements and could often lead to weight and cost reductions. However, producing an effective joint between materials with vastly different thermal, microstructural, and deformation responses is highly problematic using conventional joining and/or fastening methods. This is especially challenging in cost sensitive, high volume markets that largely rely on low cost joining solutions. Friction stir scribe technology was developed to meet the demands of joining materials with drastically different properties and melting regimes. The process enables joining of light metals like magnesium and aluminum to high temperature materials like steel and titanium. Viable joints between polymer composites and metal can also be made using this method. This paper will present the state of the art, progress made, and challenges associated with this innovative derivative of friction stir welding in reference to joining dissimilar metals and polymer/metal combinations.

Upadhyay, Piyush↗
NASA NTRS1993

A vacuum (10 exp -9 torr) friction apparatus for determining friction and endurance life of MoS(x) films

An ultrahigh-vacuum tribometer for use in a ball-on-disk configuration was specially designed for measuring the friction and endurance life of magnetron-sputtered solid lubricating MoS(x) films deposited on sputter-cleaned 400 C stainless-steel disks, when slid against a 6-mm-diameter 440 C stainless-steel ball. The results of tests showed that the tribometer performs satisfactorily in unidirectional rotation in vacuum at a pressure of 10 exp -7 Pa, 10 exp -9 torr. Similarities are observed in the life cycle friction behavior and the coefficient of friction as a function of the number of disk revolutions, for MoS(x) films at average Hertzian contact from 0.33 to 0.69 GPa.

Miyoshi, Kazuhisa↗
NASA NTRS1958

Ground Simulator Studies of the Effects of Valve Friction, Stick Friction, Flexibility, and Backwash on Power Control System Quality

Report presents results of tests made on a power control system by means of a ground simulator to determine the effects of various combinations of valve friction and stick friction on the ability of the pilot to control the system. Various friction conditions were simulated with a rigid control system, a flexible system, and a rigid system having some backlash. For the tests, the period and damping of the simulated airplane were held constant.

Brown, B Porter↗
DOE OSTI2021

Copper carbon composite wire with a uniform carbon dispersion made by friction extrusion

Copper-carbon composites are a group of materials with excellent mechanical, electrical, thermal, and tribological properties. However, bulk size copper-carbon composites made by the traditional manufacturing processes, like rolling or extrusion, fall short of reaching some of these properties predicted by theory or demonstrated only by samples at centimeter scale or smaller. The two main challenges to the successful scaling-up are: 1) to uniformly disperse carbon in the metal matrix; 2) to avoid degradation due to oxidation or reaction from overheating. In this work, we first demonstrate friction extrusion as a new method to make bulk-size void-free copper-carbon composite wires with homogenized carbon dispersion. Three different carbon varieties, graphite powder, graphene nanopowder, and carbon nanotubes, were added to the copper matrix with the concentration ranging from 0.5 wt% to 15 wt%. Special tooling, processing parameters, and procedures were developed, especially for high carbon content samples. Ten-fold reductions of both copper grain size and carbon particle size were achieved and attributed to the high shear deformation. Energy dispersive X-ray spectrometry indicates the carbon powder was refined to a sub-micron level and uniformly dispersed in the copper matrix. Compared with that of pure copper, the thermal capacity of the composite wire increases by 30 % while density reduces by 29 %.

Friction extrusion, Metal matrix composite, Graphe↗
DOE OSTI2021

Evaluation of residual stresses in isothermal friction stir welded 304L stainless steel plates

Friction stir welding was performed on 304L SS plates in order to heal simulated cracks created by electrical discharge machining. Two different tool temperatures (825 and 725 °C) were chosen for this study. Both neutron diffraction and X-ray diffraction techniques were employed to evaluate the residual stresses along two orthogonal reference directions, longitudinal (syy) and transverse (sxx). The former technique was also used to measure residual stresses at various depths. It was found that, at 1 mm depth from the top surface inside the stir zone (SZ), the longitudinal component was tensile in nature while the transverse component was compressive. The nature and magnitude of the residual stress fields, and the position of the peak residual stresses were found to vary with the weld depth. The SZ of the 725 °C weld exhibited higher peak stress than 825 °C weld mainly due to a lack of stress relief at the lower temperature.

Friction stir welding, Steel↗
DOE OSTI2021

Friction Stir Dovetailing of AA7099 to Steel with AA6061 Interlayer for Reduced Zn Embrittlement at Dissimilar Interface

Joining of high strength Al alloy (AA7099) to steel (rolled homogeneous armor) with and without AA6061 interlayer was achieved using a friction stir dovetailing (FSD) method. Detailed investigations were conducted to establish correlations between mechanical performance and microstructural evolution of FSD joints. Lap shear tensile testing revealed that incorporation of the AA6061 interlayer combined with tailored processing methodology significantly improved both mechanical interlocking and load transmission across the dovetail interface. Following incorporation of the interlayer, the maximum load carrying capacity and peak extension (of the AA7099/AA6061/steel joint) are 60% and 210% higher, respectively, than results obtained from an AA7099/steel joint without an interlayer. Without an AA6061 interlayer, formation of zinc rich intermetallic compounds led to brittle interfacial failure of the AA7099-steel FSD joint. Incorporation of novel tool and joint configuration eliminated asymmetric joint performance as a function of loading direction, which is generally observed in friction stir lap welding. The efficacy of the use of an AA6061 interlayer in joining AA7099 to steel was demonstrated through mechanical testing as well as high resolution analytical electron microscopy characterization.

Dissimilar metal joining, Friction stir dovetailin↗
DOE OSTI2017

Global energy consumption due to friction and wear in the mining industry

Calculations on the global energy consumption due to friction and wear in the mineral mining industry are presented. For the first time, the impact of wear is also included in more detailed calculations in order to show its enormous tribological and economic impacts on this industry. A large variety of mining equipment used for the extraction, haulage and beneficiation of underground mining, surface mining and mineral processing were analysed. Coefficients of friction and wear rates of moving mechanical assemblies were estimated based on available information in literature in four general cases: (1) a global average mine in use today, (2) a mine with today's best commercial technology, (3) a mine with today's most advanced technology based upon the adaptation of the latest R&D achievements, and (4) a mine with best futuristic technology forecasted in the next 10 years.

Energy↗