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At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Effect of Exchanging Advancing and Retreating Side Materials on Mechanical Properties and Electrochemical Corrosion Resistance of Dissimilar 6013-T4 and 7003 Aluminum Alloys FSW Joints

Friction stir welding (FSW) was used to weld dissimilar joints between Al 6013-T4 and Al7003 alloys in this work. The effect of exchanging advancing (AS) and retreating (RS) side material on microstructure, mechanical behaviors and electrochemical corrosion resistance was discussed. Results showed that different joint cross sections were obtained when exchanging AS and RS materials. The material on the AS would be more deformed during the welding process. When the Al6013 placed on the AS, the plastic flow of weld is more sufficient. Whether on the AS or RS, the Al6013-T4 side is the weak region for both tensile specimens and hardness samples. The fracture position corresponds to the minimum hardness position. Also, more strengthening phase can be retained in the joint, and the joint of A6R7 has better corrosion resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure Evolution and Mechanical Properties of High-Speed Friction Stir Welded Aluminum Alloy Thin Plate Joints

Sound friction stir welded (FSW) joints of 6061-T6 aluminum alloy sheets with an 0.8 mm thickness were obtained at conventional speed (2000 rpm, 300 mm/min) and high speed (11,000 rpm, 1500 mm/min). The recrystallization mechanism, precipitate evolution, mechanical properties and fracture behavior were investigated in detail. Microstructure analyses revealed that the grain structure evolution in the nugget zone (NZ) was dominated by continuous dynamic recrystallization. In the process of FSW, high speed facilitates the formation of finer equiaxed recrystallized grains, higher density of dislocations and substructures, and a larger number of precipitates in the NZ compared to the conventional speed, which further significantly improves the hardness and tensile strength of the joints. The maximum tensile strength was obtained with 292.6 MPa, 83.2% for the 6061-T6 aluminum alloy and 122.6% for the conventional-speed FSW joints. This work provides an effective method for preparing FSW aluminum alloy thin plate joints with excellent mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Study of Tribological Characteristics of Multi-pass SMAW Armox 500T Steel Joints

Study of tribological characteristics of multi-pass shielding metal arc-welded (SMAW) Armox 500T steel joints in comparison with its counterpart base metal was carried out. Series of dry sliding wear tests were carried out as a function of applied loads ranging from 30 to 120 N and sliding distances from 1000 to 6000 m at a constant sliding velocity using pin-on-disk tribometer. It was observed that specific wear rate and lost volume in SMAW joints significantly high compared to Armox 500T base metal in the range of loads and sliding distances considered in the present study. The scanning electron micrographs indicated that wear of Armox 500T base metal occurred due to micro-grooving and adhesion, on the other hand, micro-delamination was observed in SMAW joints. Microstructural investigations revealed that base metal exhibits superior tribological properties as compared to SMAW joints due to the formation of martensite lath in acicular form with coarse and fine precipitates.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Pulse MIG Welding of 6061-T6/A356-T6 Aluminum Alloy Dissimilar T-joint

Dissimilar T-joints between 4-mm-thick wrought 6061-T6 and cast A356-T6 aluminum alloy plates are made with pulse metal inert gas welding (P-MIG) process, and the weld geometry, microstructure and mechanical properties of the joints are investigated. The average tensile load of the joints is 9488 N at travel speed 12 mm/s and welding current 165 A with 6061 aluminum alloy as web plate and A356 aluminum alloy as flange plate. The weld zone (WZ) is composed of dendrite zone and columnar zone, which is wide at bottom of weld making it become a weak zone. Besides, grain boundary (GB) liquation, consisting of GB eutectic and solute-depleted α-Al, occurs in the partially melted zone on 6061 aluminum alloy side. The T-joint with highest tensile load fails at the root of WZ and the flange plate near the weld with different fracture modes.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of a Zinc Interlayer on a Cu/Al Lap Joint in Ultrasound-Assisted Friction Stir Welding

This study proposes a welding process, ultrasound-assisted friction stir welding of dissimilar Al/Cu metals. Zinc foil is melted using the heat generated by a pinless stirring tool, and the molten intermediate layer is stirred by ultrasonic cavitation to achieve an effective connection. The metallurgical reaction behavior of the joint under the action of the sound field was studied, and the effects of different microstructures on the joint performance were analyzed. Specifically, the following observations were reported in this study: (1) When ultrasound assistance was used, the cavitation effect changed the brittle intermetallic compounds of Al{sub 2}Cu from a continuous distribution to a block distribution, and the mechanical properties of the joint were greatly improved; (2) the effects of the thickness of the zinc were also determined. The results showed that the highest shear tensile force was obtained when the thickness of the zinc foil was 0.2 mm. When the thickness was 0.3 mm, the ultrasound effect was weakened. The copper-side interface generated a zigzag-shaped Al{sub 4.2}Cu{sub 3.2}Zn{sub 0.7} layer with a thickness of 3.4 μm and had a continuous distribution. Increasing the thickness of the zinc to 0.5 mm, however, drastically decreased the mechanical properties of the joint due to incomplete melting of the zinc layer.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Effective Physical Contact Area on Microstructure and Mechanical Properties of Diffusion-Bonded TC4/1060Al Joints

In the present study, dissimilar TC4 alloy and 1060Al alloy were successfully diffusion-bonded at a very low temperature about 410 °C by improving the effective physical contact area. A sound joint with a crack-free interface and a high shear strength (128 MPa) is obtained with a combination of TC4 surface roughness of 109.90 μm (S{sub a}) and 1060Al surface roughness of 101.43 μm (S{sub a}), and customized parallel surface scratches. Under this condition, the two parent metals share the largest contact area during the physical contact stage of diffusion bonding process, which is consistent with the theoretical calculation. The results show that no Ti-Al binary intermetallic compounds are observed at the interface of the joints. The maximum shear strength of the joint reaches 128 MPa with optimized bonding parameters (410 °C for 120 min with a pressure of 20 MPa), which is higher than the shear strength of 1060Al (80 MPa) base metal. The fractography analysis indicates the joints failed with a ductile fracture at the 1060Al side.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Detecting an underground tunnel by applying joint traveltime and waveform inversion

Underground tunnel and void detection is a challenging geophysical problem, and many methods have been proposed. Seismic techniques are promising because of the large seismic velocity contrasts between the air-filled void and the surrounding sediment and concrete. We apply a joint seismic traveltime and waveform inversion method to image a buried tunnel with concrete walls and a void space inside. The joint inversion images the top of the concrete tunnel as a high-velocity anomaly and the void space as a low-velocity anomaly. The location of the velocity anomalies predicted by the method agrees with the known location of the tunnel. As a comparison, the stand-alone full waveform inversion is also applied to the data. The first-arrival traveltime tomography shows weak nonlinearity but fails to image the hidden low-velocity layer. Full waveform inversion is able to image complex near-surface structures, but fitting waveforms may not honor the traveltime fit, especially when the data contain noise. Synthetic and real data tests show that the joint inversion method retains the advantages of both traveltime inversion and full waveform inversion and overcomes their respective drawbacks at the same time. The field example shows the joint inversion provides a better reconstruction of the high-velocity feature representing the top of the concrete wall in terms of its magnitude and location.

58 GEOSCIENCES↗
DOE OSTI2016

Effect of micromorphology at the fatigue crack tip on the crack growth in electron beam welded Ti-6Al-4V joint

In this paper, we describe experiments on welded joints of Ti-6Al-4V alloy specimens exhibiting fatigue characteristics in the base metal (BM), hot affected zone (HAZ) and fuse zone (FZ). The effect of micromorphology on crack propagation at the tip of the fatigue crack in joints formed by electron beam welding was investigated using an optical microscope, transmission electron microscope and other methodologies. The results demonstrated that the fatigue crack originated in and propagated along α/β boundaries in the BM. In the HAZ, the fatigue crack occurred at the boundary between martensite laths, and propagated through most irregular-equiaxed α phases and a few martensite laths. In the FZ, the fatigue crack originated at the boundaries between the fine crushing phases among martensite laths, and propagated along a majority of α/β boundaries and several narrow martensite laths. The electron beam welded joint of Ti-6Al-4V alloy showed instances of zigzag fatigue cracks that increased in degree from lowest in the HAZ, moderate in the FZ to greatest in the BM. Conversely, fatigue crack growth rate (FCGR) was greatest in the HAZ, less in the FZ and slowest in the BM. - Highlights: •Ti-6Al-4V welded joint exhibits different fatigue characteristics. •The fatigue crack propagates along α/β boundaries in the BM. •The fatigue crack propagates through α phases and martensite laths in the HAZ. •The fatigue crack propagates along α/β boundaries and martensite laths in the FZ. •Fatigue crack growth rate is fastest in the HAZ, less in the FZ, slowest in the BM.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructures and mechanical properties of the welded AA5182/HC340LA joint by magnetic pulse welding

Highlights: • The magnetic pulse welding of 5× aluminum alloy with high strength steel is performed. • The microstructure evolution of welding interface under different parameters is investigated. • The intermediate layer is characterized by high-resolution transmission electron microscope and electron diffraction pattern. - Abstract: Magnetic pulse welding (MPW) is an innovative joining technology for dissimilar materials. The MPW with high joining qualities could be realized between high strength steel and 5× aluminum alloys. In this work, the MPW joints between aluminum alloy (AA 5182) sheet and high-strength low alloy steel (HC340LA) sheet were prepared under various discharge energies. The mechanical properties and microstructure observations were employed to evaluate the joint performance. Results showed that a lower discharge voltage tended to cause joints with poor quality. When the discharge energy increased, the failure position gradually changed from the weld zone to the weaker base metal (Al) during quasi-static tensile tests. In addition, the effect of discharge energies on microstructure evolution in the intermediate layer was revealed by high-resolution transmission electron microscopy (HRTEM) and scanning electron microscope (SEM). Atomic-scale diffusion was found to be the mainly welding mechanism of the Al/Fe joint. The intermetallic compound (IMC) FeAl{sub 2} and ultra-fine grains (UFG) were found in the intermediate layer under high discharge energy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influencing mechanism of Al-containing Zn coating on interfacial microstructure and mechanical properties of friction stir spot welded Mg–steel joint

Highlights: • Al-containing Zn coating improved Mg–steel interfacial wettability during friction stir spot welding (FSSW). • Pre-existing Al{sub 5}Fe{sub 2} phase in coating on steel surface promoted Mg–steel metallurgical bonding. • A high tensile-shear load of 4.3 kN was obtained in FSSW AZ31–steel joint. - Abstract: 2.4 mm thick AZ31 Mg alloy sheet and 1.5 mm Q234 steel sheet with a hot-dipped Al-containing Zn coating were friction stir spot welded (FSSW) using a pinless tool. It was shown that the Al-containing Zn coating played a crucial role in joining the Mg alloy and steel during FSSW. The Zn coating observably improved the Mg–steel interfacial wettability during FSSW, and the Al{sub 5}Fe{sub 2} phase in the Zn coating on the steel substrate surface promoted the metallurgical bonding of Mg alloy and steel. It was confirmed that the Al{sub 5}Fe{sub 2} phase on the steel surface resulted from the reaction between the steel substrate and the Al in the Zn coating during hot-dipping, and was not related to the Al-containing Mg alloy substrate. The tensile-shear load of the FSSW Mg–steel joint reached 4.3 kN. The fracture of the joint occurred along the interface on the steel substrate side. The interface between the Al{sub 5}Fe{sub 2} layer and Mg alloy substrate was the weakest region of the Mg–steel joint.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

Microstructure characterization and thermal stability of TC11/Ti2AlNb joints during thermal exposure

Highlights: • Mechanical properties of TC11/Ti{sub 2}AlNb deteriorate due to coarsening of O and α{sub s}. • Thermal stability of α{sub s} phase is lower than that of O phase during exposure. • A relationship was found between the reduction of area and phase thickness. - Abstract: TC11/Ti{sub 2}AlNb welding joints undergoing hot deformation were thermally exposed at the range of 500–700 °C for 100, 200 and 500 h. In present research, typical microstructures of five different zones of the joints were investigated, fusion zone, two interfaces and two base alloys included. The microstructures of fusion zone, Ti{sub 2}AlNb-based alloy and the interface between them were characterized by the coarsening of O phase during thermal exposure, while those of TC11 alloy and the interface between it and fusion zone featured the coarsening of α{sub s} phase. The transformation from B2 to β and O phase was stifled below 600 °C and Ti{sub 2}AlNb-based alloy thus was verified to be stable at this temperature range. α{sub s} phase was stable during exposure at 500 °C. When exposed above 600 °C, α{sub s} phase coarsened by at least 52% with the extension of holding time. Due to the low thermal stability of α{sub s} phase compared with that of O phase, the fracture position of the samples tested at room temperature moved from fusion zone to TC11 alloy when temperature rose. In spite of different thermal exposure conditions, the samples tested at 300 and 500 °C all fractured at TC11 alloy for the severe coarsening of α{sub s} phase. The decrease of interfacial area resulting from the coarsening of O and α{sub s} phases facilitated the dislocation slipping and the strength of joints thus deteriorated. The mechanical properties of TC11/Ti{sub 2}AlNb joints measured at room temperature, 300 and 500 °C were all correlated with the lamellar thickness of O and α{sub s} phases.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Using DR52c/Ni{sup 2+} mimotope tetramers to detect Ni{sup 2+} reactive CD4{sup +} T cells in patients with joint replacement failure

T cell mediated hypersensitivity to nickel (Ni{sup 2+}) is one of the most common causes of allergic contact dermatitis. Ni{sup 2+} sensitization may also contribute to the failure of Ni{sup 2+} containing joint implants, and revision to non-Ni{sup 2+} containing hardware can be costly and debilitating. Previously, we identified Ni{sup 2+} mimotope peptides, which are reactive to a CD4{sup +} T cell clone, ANi2.3 (Vα1, Vβ17), isolated from a Ni{sup 2+} hypersensitive patient with contact dermatitis. This T cell is restricted to the major histocompatibility complex class II (MHCII) molecule, Human Leukocyte Antigen (HLA)-DR52c (DRA, DRB3*0301). However, it is not known if Ni{sup 2+} induced T cell responses in sensitized joint replacement failure patients are similar to subjects with Ni{sup 2+} induced contact dermatitis. Here, we generated DR52c/Ni{sup 2+} mimotope tetramers, and used them to test if the same Ni{sup 2+} T cell activation mechanism could be generalized to Ni{sup 2+} sensitized patients with associated joint implant failure. We confirmed the specificity of these tetramers by staining of ANi2.3 T cell transfectomas. The DR52c/Ni{sup 2+} mimotope tetramer detected Ni{sup 2+} reactive CD4{sup +} T cells in the peripheral blood mononuclear cells (PBMC) of patients identified as Ni{sup 2+} sensitized by patch testing and a positive Ni{sup 2+} LPT. When HLA-typed by a DR52 specific antibody, three out of four patients were DR52 positive. In one patient, Ni{sup 2+} stimulation induced the expansion of Vβ17 positive CD4{sup +} T cells from 0.8% to 13.3%. We found that the percentage of DR52 positivity and Vβ17 usage in Ni{sup 2+} sensitized joint failure patients are similar to Ni sensitized skin allergy patients. Ni{sup 2+} independent mimotope tetramers may be a useful tool to identify the Ni{sup 2+} reactive CD4{sup +} T cells. - Highlight: • Nickel hypersensitive patients with implant failure are dominantly DR52 positive. • These patients may have similar TCR beta chain usage to that of contact dermatitis. • The nickel mimotope tetramers are a tool to identify the nickel reactive CD4{sup +} T cells.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Observations of modal coupling due to bolted joints in an experimental benchmark structure

The goal of this paper is to present a set of measurements from a benchmark structure containing two bolted joints to support future efforts to predict the damping due to the joints and to model nonlinear coupling between the first two elastic modes. Bolted joints introduce nonlinearities in structures, typically causing a softening in the natural frequency and an increase in damping because of frictional slip between the contact interfaces within the joint. These nonlinearities pose significant challenges when characterizing the response of the structure under a large range of load amplitudes, especially when the modal responses become coupled, causing the effective damping and natural frequency to not only depend on the excitation amplitude of the targeted mode, but also the relative amplitudes of other modes. In this work, two nominally identical benchmark structures, known in some prior works as the S4 beam, are tested to characterize their nonlinear properties for the first two elastic modes. Detailed surface measurements are presented and validated through finite element analysis and reveal distinct contact interactions between the two sets of beams. The free-free test structures are excited with an impact hammer and the transient response is analyzed to extract the damping and frequency backbone curves. A range of impact amplitudes and drive points are used to isolate a single mode or to excite both modes simultaneously. Differences in the nonlinear response correlate with the relative strength of the modes that are excited, allowing one to characterize mode coupling. Each of the beams shows different nonlinear properties for each mode, which is attributed to the different contact pressure distributions between the parts, although the mode coupling relationship is found to be consistent between the two. Lastly, the test data key finding are presented in this paper and the supporting data is available on a public repository for interested researchers.

42 ENGINEERING↗
DOE OSTI2020

The Sensitivity of Joint Inversions of Seismic and Geodynamic Data to Mantle Viscosity

Seismic tomography has revealed the existence of large-scale velocity heterogeneities in the mantle. The interpretation of seismic velocity anomalies in terms of temperature and chemical composition is nonunique. We use geodynamic observations including gravity, plate motions, dynamic topography, and excess ellipticity of the core-mantle boundary combined with seismic observations to investigate the thermo-chemical structure of the mantle through joint inversions. An outstanding issue, however, is the physical connection between mantle density anomalies and the surface geodynamic observations, which requires knowledge of the mantle viscosity structure. Here we perform joint inversions assuming different viscosity profiles and examine the dependence of the results on the viscosity. We first assume that mantle heterogeneity is due to thermal variations, which places a constraint on the relation between seismic velocity and density, and we subsequently relax the constraint to allow for potential nonthermal effects. In all of our joint inversions, a nonthermal origin of density anomalies is required to explain the geodynamic data, though the amount varies with the assumed viscosity structure. A common observation is a high-density chemical signal in the center of the large low-shear-velocity provinces at the base of the mantle resulting in a near neutral or slightly dense overall buoyancy there. Using the derived density models and their corresponding viscosity profiles, we also calculate instantaneous mantle flow fields. The predicted flow fields derived from joint inversions are generally similar but are quite different from flow fields using density models derived from a posteriori scaling of pure seismic tomography models.

58 GEOSCIENCES↗
DOE OSTI2022

Joint Inversion of Body Wave Arrival Times, Surface Wave Dispersion Data and Receiver Functions: Method and Application to South China

In this work, we have developed a new joint inversion method that incorporates body wave arrival times, surface wave dispersion and receiver functions to simultaneously update earthquake locations and constrain three-dimensional P-wave (Vp) and S-wave velocity (Vs) models. Due to complementary sensitivities of the three types of data, the proposed joint inversion algorithm can reduce the intrinsic non-uniqueness of inversions using fewer types of data and better determine smooth velocity variations and velocity discontinuities. Synthetic tests demonstrate the advantages of this new joint inversion algorithm in resolving velocity structures, especially in constraining velocity gradients across the Moho interface. We have applied the proposed joint inversion algorithm to image the lithosphere velocity structure of south China. The inverted Vp and Vs models fit body wave arrival times, surface wave dispersion and receiver functions well. We further analyzed the distribution of Vs gradients across the Moho interface in detail, which helps us better understand tectonics in south China.

58 GEOSCIENCES↗
DOE OSTI2015

Effect of gamma radiation on micromechanical hardness of lead-free solder joint

Lead-free solders are important material in nano and microelectronic surface mounting technology for various applications in bio medicine, environmental monitoring, spacecraft and satellite instrumentation. Nevertheless solder joint in radiation environment needs higher reliability and resistance to any damage caused by ionizing radiations. In this study a lead-free 99.0Sn0.3Ag0.7Cu wt.% (SAC) solder joint was developed and subjected to various doses of gamma radiation to investigate the effects of the ionizing radiation to micromechanical hardness of the solder. Averaged hardness of the SAC joint was obtained from nanoindentation test. The results show a relationship between hardness values of indentations and the increment of radiation dose. Highest mean hardness, 0.2290 ± 0.0270 GPa was calculated on solder joint which was exposed to 5 Gray dose of gamma radiation. This value indicates possible radiation hardening effect on irradiated solder. The hardness gradually decreased to 0.1933 ± 0.0210 GPa and 0.1631 ± 0.0173 GPa when exposed to doses 50 and 500 gray respectively. These values are also lower than the hardness of non irradiated sample which was calculated as 0.2084 ± 0.0.3633 GPa indicating possible radiation damage and needs further related atomic dislocation study.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Review on failure prediction techniques of composite single lap joint

Adhesive bonding is the most appropriate joining method in construction of composite structures. The use of reliable design and prediction technique will produce better performance of bonded joints. Several papers from recent papers and journals have been reviewed and synthesized to understand the current state of the art in this area. It is done by studying the most relevant analytical solutions for composite adherends with start of reviewing the most fundamental ones involving beam/plate theory. It is then extended to review single lap joint non linearity and failure prediction and finally on the failure prediction on composite single lap joint. The review also encompasses the finite element modelling part as tool to predict the elastic response of composite single lap joint and failure prediction numerically.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Interdependence in active mobility adoption: Joint modeling and motivational spillover in walking, cycling and bike-sharing

Active mobility offers an array of physical, emotional, and social well-being benefits. However, with the proliferation of the sharing economy, new nonmotorized means of transport are entering the fold, complementing some existing mobility options while competing with others. The purpose of this research study is to investigate the adoption of three active travel modes—namely walking, cycling, and bikesharing—in a joint modeling framework. Here, the analysis is based on an adaptation of the stages of change framework, which originates from the health behavior sciences. Multivariate ordered probit modeling drawing on U.S. survey data provides well-needed insights into individuals’ preparedness to adopt multiple active modes as a function of personal, neighborhood, and psychosocial factors. The research suggests three important findings. (1) The joint model structure confirms interdependence among different active mobility choices. The strongest complementarity is found for walking and cycling adoption. (2) Each mode has a distinctive adoption path with either three or four separate stages. We discuss the implications of derived stage-thresholds and plot adoption contours for selected scenarios. (3) Psychological and neighborhood variables generate more coupling among active modes than individual and household factors. Specifically, identifying strongly with active mobility aspirations, experiences with multimodal travel, possessing better navigational skills, along with supportive local community norms are the factors that appear to drive the joint adoption decisions. This study contributes to the understanding of how decisions within the same functional domain are related and help to design policies that promote active mobility by identifying positive spillovers and joint determinants.

42 ENGINEERING↗