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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.

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354 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Characterization of Multilayered Multipass Friction Stir Weld on ASTM A572 G50 Steel

A multilayered multipass friction stir weld (MM-FSW) on ASTM A572 Grade 50 steel was characterized to understand its potential application for thick-section structures. The 15-mm-thick section was fabricated by stacking up three steel plates and then friction stir welding the plates together in a total of 5 passes. The unique butt/lap joint configuration encountered in the multilayer weld was examined to understand the effect of tool rotation direction on the joint quality especially the formation of hooking defect. Charpy V-notch impact toughness tests showed generally higher impact toughness energy for the stir zone than the base metal with a ductile fracture mode. The microhardness value was measured from 195 to 220 HV in the stir zone, while the base metal showed an average value of 170 HV. The microstructure in the stir zone and the adjacent heat affected zone was quantified using Optical and Scanning Electron Microscopy (SEM) including Electron Backscatter Diffraction (EBSD). The increased toughness and hardness were correlated with the refined microstructure in stir zone, resulting from severe plastic deformation and subsequent dynamic recrystallization during friction stir welding.

Lim, Yong Chae↗
DOE OSTI2018

ADVANCED WELDING TECHNOLOGY DEVELOPMENT FOR NUCLEAR REACTOR REPAIR

Welding is widely used for repair, maintenance, and upgrade of nuclear reactor components. As a critical technology for supporting the extension of nuclear power plant service lifetimes beyond 60 years, there has been an industry need in further developing welding technology for highly irradiated materials. During welding of irradiated materials, Helium, which is a transmutation byproduct from Boron and Nickel contained in the structural alloys, can coalesce into bubbles along grain boundaries in the material under driving forces of high temperature and thermal tensile stress. This leads to embrittlement and potential intergranular cracking in the Heat Affected Zone (HAZ) of the weld. In this paper, irradiated 304 stainless steel coupons containing 5, 10 and 20 ppm Boron prior to radiation were successfully welded by advanced laser beam welding (LBW) and friction stir welding (FSW). Facilities and welding machine design, welding processes development, cold material welded joints evaluation, process safety control and documentation, and irradiated material welding are discussed. Both laser and friction stir welded coupons of the irradiated material exhibited high welding quality and surface finish. No Helium induced welding defects were observed on the weld surfaces or adjacent base metals.

Tang, Wei↗
DOE OSTI2020

System and method for light assisted friction stir processing and welding of metallic and non-metallic materials

An apparatus for use in a friction stir operation, such as friction stir welding (FSW) or friction stir processing (FSP). The apparatus may have a rotating tool adapted to be plunged into a material, where the material is susceptible to being softened by heating. The rotating tool may further be adapted to be advanced along a surface of the material. An optical energy generating subsystem may be used to heat a portion of the material using optical energy as the tool is advanced along the material.

42 ENGINEERING↗
DOE OSTI2015

Thermal Microstructural Stability of AZ31 Magnesium after Severe Plastic Deformation

Both equal channel angular pressing and friction stir processing have the ability to refine the grain size of twin roll cast AZ31 magnesium and potentially improve its superplastic properties. This work used isochronal and isothermal heat treatments to investigate the microstructural stability of twin roll cast, equal channel angular pressed and friction stir processed AZ31 magnesium. For both heat treatment conditions, it was found that the twin roll casted and equal channel angular pressed materials were more stable than the friction stir processed material. Calculations of the grain growth kinetics showed that severe plastic deformation processing decreased the activation energy for grain boundary motion with the equal channel angular pressed material having the greatest Q value of the severely plastically deformed materials and that increasing the tool travel speed of the friction stir processed material improved microstructural stability. The Hollomon-Jaffe parameter was found to be an accurate means of identifying the annealing conditions that will result in substantial grain growth and loss of potential superplastic properties in the severely plastically deformed materials. In addition, Humphreys’s model of cellular microstructural stability accurately predicted the relative microstructural stability of the severely plastically deformed materials and with some modification, closely predicted the maximum grain size ratio achieved by the severely plastically deformed materials.

FSW↗
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 OSTI2014

Comparing Laser Welding Technologies with Friction Stir Welding for Production of Aluminum Tailor-Welded Blanks

A comparison of welding techniques was performed to determine the most effective method for producing aluminum tailor-welded blanks for high volume automotive applications. Aluminum sheet was joined with an emphasis on post weld formability, surface quality and weld speed. Comparative results from several laser based welding techniques along with friction stir welding are presented. The results of this study demonstrate a quantitative comparison of weld methodologies in preparing tailor-welded aluminum stampings for high volume production in the automotive industry. Evaluation of nearly a dozen welding variations ultimately led to down selecting a single process based on post-weld quality and performance.

aluminum↗
NASA NTRS2008

JPL Fault Protection Software Experiences

This objectives of this slide presentation are to: (1) Share JPL experiences by describing the evolution of fault protection during its history in deep space exploration, (2) Examine issues of fault protection scope and implementation that affect missions today, and (3) Discuss solutions for the problems of today and tomorrow.

Flight Software(FSW)complexity↗
NASA NTRS2011

Mars Science Laboratory Flight Software Boot Robustness Testing Project Report

On the surface of Mars, the Mars Science Laboratory will boot up its flight computers every morning, having charged the batteries through the night. This boot process is complicated, critical, and affected by numerous hardware states that can be difficult to test. The hardware test beds do not facilitate testing a long duration of back-to-back unmanned automated tests, and although the software simulation has provided the necessary functionality and fidelity for this boot testing, there has not been support for the full flexibility necessary for this task. Therefore to perform this testing a framework has been build around the software simulation that supports running automated tests loading a variety of starting configurations for software and hardware states. This implementation has been tested against the nominal cases to validate the methodology, and support for configuring off-nominal cases is ongoing. The implication of this testing is that the introduction of input configurations that have yet proved difficult to test may reveal boot scenarios worth higher fidelity investigation, and in other cases increase confidence in the robustness of the flight software boot process.

Mars Science Laboratory (MSL)↗
NASA NTRSDate not supplied

MAV Software Development: Streamlined Collaboration for MSR

This poster presents the coordinated efforts of the Mars Ascent Vehicle (MAV) software development teams, encompassing Flight Software, Ground Software, and Hardware-in-the-Loop Labs. This collaborative approach, which stems from the Artemis program, ensures efficiency in preparing for the Mars Sample Return (MSR) mission, focusing on the critical role of software integration for mission success.

MAV↗
DOE OSTI2021

Process Robustness of Friction Stir Dovetailing of AA7099 to Steel with In Situ AA6061 Interlayer Linking

Rolled homogeneous armor (RHA) steel was joined to aluminum alloy AA7099-T7451 with an interlayer of AA6061-T651 by single-pass friction stir dovetailing (FSD). The evolution of the AA7099/AA6061 and AA6061/steel interfacial microstructures and mechanical properties of the joints were examined. The AA6061 interlayer prevented Zn migration from the AA7099 to the steel during FSD and inhibited formation of brittle, Zn-rich, Fe-Al intermetallic compounds within the joint. The flow of the dissimilar aluminum alloys at the interface was controlled with a partially threaded friction stir welding pin and a dovetail geometric configuration optimized in previous work. The process robustness was explored to establish parameter windows by elucidating parametric effects on the relationship between process conditions and the joint’s microstructure and mechanical properties. Ranges of process forge force (50–70 kN) and interface temperature (475°C–515°C) consistently yielded joints with adequate performance. The load-carrying capacity in lap shear tensile tests was 2025 ? 100 N/mm.

Friction Stir Dovetailing, FSW, AA7099, AA6061, Ro↗