Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Joint strength”

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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Evaluation of the Transient Liquid Phase (TLP) Bonding Process for Ti3Al-Based Honeycomb Core Sandwich Structure

The suitability of using transient liquid phase (TLP) bonding to fabricate honeycomb core sandwich panels with Ti-14Al-21Nb (wt%) titanium aluminide (T3Al) face sheets for high-temperature hypersonic vehicle applications was evaluated. Three titanium alloy honeycomb cores and one Ti3Al alloy honeycomb core were investigated. Edgewise compression (EWC) and flatwise tension (FWT) tests on honeycomb core sandwich specimens and tensile tests of the face sheet material were conducted at temperatures ranging from room temperature to 1500 F. EWC tests indicated that the honeycomb cores and diffusion bonded joints were able to stabilize the face sheets up to and beyond the face sheet compressive yield strength for all temperatures investigated. The specimens with the T3Al honeycomb core produced the highest FWT strengths at temperatures above 1000 F. Tensile tests indicated that TLP processing conditions resulted in decreases in ductility of the Ti-14Al-21Nb face sheets. Microstructural examination showed that the side of the face sheets to which the filler metals had been applied was transformed from equiaxed alpha2 grains to coarse plates of alpha2 with intergranular Beta. Fractographic examination of the tensile specimens showed that this transformed region was dominated by brittle fracture.

Bird, R. Keith↗
NASA NTRS2004

The In-Space Soldering Investigation: Research Conducted on the International Space Station in Support of NASA's Exploration Initiative

Soldering is a well established joining and repair process that is of particular importance in the electronics industry. Still. internal solder joint defects such as porosity are prevalent and compromise desired properties such as electrical/thermal conductivity and fatigue strength. Soldering equipment resides aboard the International Space Station (ISS) and will likely accompany Exploration Missions during transit to, as well as on, the moon and Mars. Unfortunately, detrimental porosity appears to be enhanced in lower gravity environments. To this end, the In-Space Soldering Investigation (ISSI) is being conducted in the Microgravity Workbench Area (MWA) aboard the ISS as "Saturday Science" with the goal of promoting our understanding of joining techniques, shape equilibrium, wetting phenomena, and microstructural development in a microgravity environment. The work presented here will focus on direct observation of melting dynamics and shape determination in comparison to ground-based samples, with implications made to processing in other low-gravity environments. Unexpected convection effects, masked on Earth, will also be shown as well as the value of the ISS as a research platform in support of Exploration Missions.

Grugel, R. N.↗
NASA NTRS2006

The In-Space Soldering Investigation: To Date Analysis of Experiments Conducted on the International Space Station

Soldering is a well established joining and repair process that is of particular importance in the electronics industry. Still, internal solder joint defects such as porosity are prevalent and compromise desired properties such as electrical/thermal conductivity and fatigue strength. Soldering equipment resides aboard the International Space Station (ISS) and will likely accompany Exploration Missions during transit to, as well as on, the moon and Mars. Unfortunately, detrimental porosity appears to be enhanced in lower gravity environments. To this end, the In-Space Soldering Investigation (ISSI) is being conducted in the Microgravity Workbench Area (MWA) aboard the ISS as "Saturday Science" with the goal of promoting our understanding of joining techniques, shape equilibrium, wetting phenomena, and microstructural development in a microgravity environment. The work presented here will focus on direct observation of melting dynamics and shape determination in comparison to ground-based samples, with implications made to processing in other low-gravity environments. Unexpected convection effects, masked on Earth, will also be shown as well as the value of the ISS as a research platform in support of Exploration Missions.

Grugel, Richard N.↗
NASA NTRS2014

Development of a Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

An invention of a new and novel space robotic manipulator is described. By using a combination of lightweight truss links, a novel hinge joint, tendon-articulation and passive tension stiffening, this new robotic manipulator architecture achieves compact packaging, high strength, stiffness and dexterity while being very lightweight compared to conventional manipulators. The manipulator is also very modular; easy to scale for different reach, load and stiffness requirements; enabling customization for a diverse set of applications. Novel features of the new manipulator concept are described as well as some of the approaches to implement these design features. Two diverse applications are presented to show the versatility of the concept. First generation prototype hardware was designed, manufactured and has been assembled into a working manipulator that is being used to refine and extend development efforts.

Doggett, William R.↗
NASA NTRS2014

Development of a Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN)

An invention of a new and novel space robotic manipulator is described. By using a combination of lightweight truss links, a novel hinge joint, tendon-articulation and passive tension stiffening, this new robotic manipulator architecture achieves compact packaging, high strength, stiffness and dexterity while being very lightweight compared to conventional manipulators. The manipulator is also very modular; easy to scale for different reach, load and stiffness requirements; enabling customization for a diverse set of applications. Novel features of the new manipulator concept are described as well as some of the approaches to implement these design features. Two diverse applications are presented to show the versatility of the concept. First generation prototype hardware was designed, manufactured and has been assembled into a working manipulator that is being used to refine and extend development efforts.

Doggett, William R.↗
DOE OSTI2021

Optimization of the microstructure and mechanical properties of electron beam welded high-strength medium-entropy alloy (NiCoCr) 94 Al 3 Ti 3

For this work, the weldability and effects of subsequent heat treatment on the microstructure and mechanical properties of the medium-entropy alloy (MEA) (NiCoCr) 94 Al 3 Ti 3 have been explored using electron beam welding (EBW). It was found that EBW joints consist of a supersaturated f.c.c. matrix with coarse, asymmetric columnar grains (17.7–24 μm). The fraction of twins and Σ3 n CSL boundaries in weld joints was only 10% of that in the base metal, a value which increased to 30% after aging at 800 °C. The aging also led to improvements in the hardness, tensile strength, and work hardening rate, a result of the precipitation of a high volume fraction (0.29–0.33) of ultrafine (15–17.4 nm dia.) coherent spherical L1 2 -structured particles. The contributions of the L1 2 nanoparticles and Hall-Petch strengthening to the yield strength were estimated to be 537–573 MPa and 105–123 MPa, respectively. The MEA shows excellent weldability and, after aging, good strength (YS~1098 MPa, UTS~1368 MPa) and elongation to failure (~11%) by ductile fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2025

ASSESSING THE EFFECTIVENESS OF ULTRASONIC IMPACT TREATMENT ON RESIDUAL STRESS PROFILES IN DISSIMILAR WELDED JOINTS

Residual stresses (RS) induced during welding processes are a critical concern in materials engineering, as they can significantly impair the mechanical performance of components by reducing fatigue strength and tensile load capacity. This challenge is especially pronounced in dissimilar metal welds (DMWs), where variations in thermal expansion properties between the joined alloys exacerbate the formation of tensile RS. Conventional post-weld heat treatments, though effective for homogeneous materials, often require substantial energy, specialized equipment, and extensive processing time, making them less practical for DMW applications. Thus, there is a clear need for innovative, energy-efficient techniques to mitigate these detrimental stresses. This study investigates ultrasonic impact treatment (UIT) as a possible alternative for mitigating tensile RS in both similar and dissimilar metal welds. To evaluate UIT’s effectiveness, neutron diffraction (ND) was employed as a nondestructive technique to quantify RS in three orthogonal directions—longitudinal, transverse, and normal. The results showed that UIT significantly reduced peak tensile RS, particularly in the longitudinal direction, by up to 180 MPa in similar welds and up to 150 MPa in dissimilar welds. Given the limited literature on UIT application in DMWs, this work contributes valuable data on stress redistribution mechanisms and highlights UIT’s potential as a practical stress-relief method. The findings lay the groundwork for further investigations aimed at optimizing process parameters and understanding long-term performance in welded joints.

EisaZadeh, Hamid [Western Carolina University, Cul↗
NASA NTRS1992

Ten-year space launch technology plan

This document is the response to the National Space Policy Directive-4 (NSPD-4), signed by the President on 10 Jul. 1991. Directive NSPD-4 calls upon the Department of Defense (DoD), the Department of Energy (DOE), and the National Aeronautics and Space Administration (NASA) to coordinate national space launch technology efforts and to jointly prepare a 10-year space launch technology plan. The nation's future in space rests on the strength of its national launch technology program. This plan documents our current launch technology efforts, plans for future initiatives in this arena, and the overarching philosophy that links these activities into an integrated national technology program.

Source record↗
NASA NTRS2003

Investigation Leads to Improved Understanding of Space Shuttle RSRM Internal Insulation Joints

The Space Shuttle Reusable Solid Rocket Motor (RSRM) uses an internal insulation J-joint design for the mated insulation interface between two assembled RSRM segments. In this assembled (mated) segment configuration, this J-joint design serves as a thermal barrier to prevent hot gases from affecting the case field joint metal surfaces and O-rings. A pressure sensitive adhesive (PSA) provides some adhesion between the two mated insulation surfaces. In 1995, after extensive testing, a new ODC-free PSA (free of ozone depleting chemicals) was selected for flight on RSRM-55 (STS-78). Post-flight inspection revealed that the J-joint, equipped with the new ODC-free PSA, did not perform well. Hot gas seeped inside the J-joint interface. Although not a flight safety threat, the J-joint hot gas intrusion on RSRM-55 was a mystery to the investigators since the PSA had previously worked well on a full-scale static test. A team was assembled to study the J-joint and PSA further. All J-joint design parameters, measured data, and historical performance data were re-reviewed and evaluated by subscale testing and analysis. Although both the ODC-free and old PSA were weakened by humidity, the ODC-free PSA strength was lower to start with. Another RSRM full-scale static test was conducted in 1998 and intentionally duplicated the gas intrusion. This test, along with many concurring tests, showed that if a J-joint was 1) mated with the new ODC-free PSA, 2) exposed to a history of high humidity (Kennedy Space Center levels), and 3) also a joint which experienced significant but normal joint motion (J-joint deformation resulting from motor pressurization dynamics) then that J-joint would open (allow gas intrusion) during motor operation. When all of the data from the analyses, subscale tests, and full-scale tests were considered together, a theory emerged. Most of the joint motion on the RSRM occurs early in motor operation at which point the J-joints are pulled into tension. If the new PSA has been weakened due to humidity, then the J-joint will partially pull apart (inboard side), and the J-joint surfaces will be charred by exposure to hot gases. After early operation, a J-joint that has been pulled apart will come back together as the J-joint deformation decreases. This J-joint heating event is relatively short and occurs only during the first part of motor operation. Internal instrumentation was developed for another full-scale static test in February 2000. The static test instrumentation did indeed prove this theory to be correct. Post-test inspection revealed very similar charring characteristics as observed on RSRM-55. This experience of the development of a new PSA, its testing, the RSRM-55 flight, followed by the J-joint investigation led to good 'lessons learned' and to an additional fundamental understanding of the RSRM J-joint function.

McWhorter, Bruce B.↗
NASA NTRS1985

The Strength and Characteristics of VPPA Welded 2219-T87 Aluminum Alloy

A study of the variable polarity plasma arc (VPPA) welding process and those factors that control the structure and properties of VPPA welded aluminum alloy 2219-T87 was conducted. The importance of joint preparation, alignment of parts and welding process variables are already established. Internal weld defects have been eliminated. However, a variation of properties was found to be due to the size variation of interdendritic particles in the fusion zone. These particles contribute to the void formation process, which controls the ultimate tensile strength of the welded alloy. A variation of 150 microns in particle size correlated with a 10 ksi variation of ultimate tensile strength. It was found that all fracture surfaces were of the dimple rupture type, with fracture initiating within the fusion zone.

Jemian, W. A.↗
DOE OSTI2025

Machine learning inversion from small-angle scattering for charged polymers

We develop Monte Carlo simulations for uniformly charged polymers and a machine learning algorithm to interpret the intra-polymer structure factor of the charged polymer system, which can be obtained from small-angle scattering experiments. The polymer is modeled as a chain of fixed-length bonds, where the connected bonds are subject to bending energy, and there is also a screened Coulomb potential for charge interaction between all joints. The bending energy is determined by the intrinsic bending stiffness, and the charge interaction depends on the interaction strength and screening length. All three contribute to the stiffness of the polymer chain and lead to longer and larger polymer conformations. The screening length also introduces a second length scale for the polymer besides the bending persistence length. To obtain the inverse mapping from the structure factor to these polymer conformation and energy-related parameters, we generate a large data set of structure factors by running simulations for a wide range of polymer energy parameters. We use principal component analysis to investigate the intra-polymer structure factors and determine the feasibility of the inversion using the nearest neighbor distance. We employ Gaussian process regression to achieve the inverse mapping and extract the characteristic parameters of polymers from the structure factor with low relative error.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Rutherford-in-Copper-Channel Conductor for the MARCO Solenoidal Detector Magnet

MARCO will be a superconducting solenoid for a new particle physics detector of the upcoming Electron Ion Collider (EIC) at Brookhaven National Laboratory (NY, USA). The design field at the interaction point is 2.0 T with a nominal current of about 4 kA at 4.5 K. For this magnet, an aluminumstabilized conductor was considered at the very preliminary design phase. After that, since the lack of manufacturers able to deal with aluminum extrusion, copper has been chosen as stabilizer. Thanks to a dedicated design effort, the copper stabilizer and accompanying material choices provided acceptable hadronic interaction length. The conductor is based on a NbTi Rutherford cable that is soldered in a U-shaped copper profile. Here, this paper goes through the definition of the conductor crosssection according to the project requirements and the supplier capabilities. Its characteristics will be detailed and discussed, in particular the RRR and the yield strength of the copper channel needed for protection and mechanics respectively. Finally, a proposal on how to make the joint between two conductors is presented.

Stacchi, Francesco [Commissariat a l'Energie Atomi↗
NASA NTRS1993

Characteristics of products generated by selective sintering and stereolithography rapid prototyping processes

The trend in the modern global economy towards free market policies has motivated companies to use rapid prototyping technologies to not only reduce product development cycle time but also to maintain their competitive edge. A rapid prototyping technology is one which combines computer aided design with computer controlled tracking of focussed high energy source (eg. lasers, heat) on modern ceramic powders, metallic powders, plastics or photosensitive liquid resins in order to produce prototypes or models. At present, except for the process of shape melting, most rapid prototyping processes generate products that are only dimensionally similar to those of the desired end product. There is an urgent need, therefore, to enhance the understanding of the characteristics of these processes in order to realize their potential for production. Currently, the commercial market is dominated by four rapid prototyping processes, namely selective laser sintering, stereolithography, fused deposition modelling and laminated object manufacturing. This phase of the research has focussed on the selective laser sintering and stereolithography rapid prototyping processes. A theoretical model for these processes is under development. Different rapid prototyping sites supplied test specimens (based on ASTM 638-84, Type I) that have been measured and tested to provide a data base on surface finish, dimensional variation and ultimate tensile strength. Further plans call for developing and verifying the theoretical models by carefully designed experiments. This will be a joint effort between NASA and other prototyping centers to generate a larger database, thus encouraging more widespread usage by product designers.

Cariapa, Vikram↗
NASA NTRS2012

Simulation and Flight Test Capability for Testing Prototype Sense and Avoid System Elements

NASA Langley Research Center (LaRC) and The MITRE Corporation (MITRE) have developed, and successfully demonstrated, an integrated simulation-to-flight capability for evaluating sense and avoid (SAA) system elements. This integrated capability consists of a MITRE developed fast-time computer simulation for evaluating SAA algorithms, and a NASA LaRC surrogate unmanned aircraft system (UAS) equipped to support hardware and software in-the-loop evaluation of SAA system elements (e.g., algorithms, sensors, architecture, communications, autonomous systems), concepts, and procedures. The fast-time computer simulation subjects algorithms to simulated flight encounters/ conditions and generates a fitness report that records strengths, weaknesses, and overall performance. Reviewed algorithms (and their fitness report) are then transferred to NASA LaRC where additional (joint) airworthiness evaluations are performed on the candidate SAA system-element configurations, concepts, and/or procedures of interest; software and hardware components are integrated into the Surrogate UAS research systems; and flight safety and mission planning activities are completed. Onboard the Surrogate UAS, candidate SAA system element configurations, concepts, and/or procedures are subjected to flight evaluations and in-flight performance is monitored. The Surrogate UAS, which can be controlled remotely via generic Ground Station uplink or automatically via onboard systems, operates with a NASA Safety Pilot/Pilot in Command onboard to permit safe operations in mixed airspace with manned aircraft. An end-to-end demonstration of a typical application of the capability was performed in non-exclusionary airspace in October 2011; additional research, development, flight testing, and evaluation efforts using this integrated capability are planned throughout fiscal year 2012 and 2013.

Howell, Charles T.↗
NASA NTRS2015

Non-destructive Evaluation of Bonds Between Fiberglass Composite and Metal

To assess the integrity and reliability of an adhesive joint in an automotive composite component, several non-destructive evaluation (NDE) methodologies are correlated to lap shear bond strengths. A glass-fabric-reinforced composite structure was bonded to a metallic structure with a two-part epoxy adhesive. Samples were subsequently cut and tested in shear, and flaws were found in some areas. This study aims to develop a reliable and portable NDE system for service-level adhesive inspection in the automotive industry. The results of the experimental investigation using several NDE methods are presented and discussed. Fiberglass-to-metal bonding is the ideal configuration for NDE via thermography using excitation with induction heating, due to the conductive metal and non-conductive glass-fiber-reinforced composites. Excitation can be either by a research-grade induction heater of highly defined frequency and intensity, or by a service-level heater, such as would be used for sealing windshields in a body shop. The thermographs thus produced can be captured via a high-resolution infrared camera, with principal component analysis and 2D spatial Laplacian processing. Alternatively, the thermographs can be captured by low resolution thermochromic microencapsulated liquid crystal film imaging, which needs no post-processing and can be very inexpensive. These samples were also examined with phased-array ultrasound. The NDE methods are compared to the lap shear values and to each other for approximate cost, accuracy, and time and level of expertise needed.

Zhao, Selina↗
DOE OSTI2020

Joint Appointments: General Principles for Joint Appointments between LANL and University Partners

The Joint Appointment Program provides opportunities for LANL and partner universities to recruit, retain, and recognize premier scientists and engineers by offering them the ability to work in both the LANL and university environments. These interactions enhance the ability of both institutions to achieve their respective research and development missions while providing increased academic strength to educational institutions.

96 KNOWLEDGE MANAGEMENT AND PRESERVATION↗
DOE OSTI2020

Microstructure and strength of a thick-section gas-tungsten arc weld in cast Haynes® 282® alloy

A 50-mm deep gas tungsten arc weld was made with matching filler metal in cast Haynes 282 alloy. The narrow gap joint was filled with 104 weld beads. The weld deposit was of high quality with no visible indications of physical defects. The weld heat-affected zone was characterized by microcracking and localized recrystallization. Hardness testing showed that a softened region in the as-welded heat-affected zone was nearly eliminated by post-weld heat treatment. Tensile testing up to 816°C showed that cross-weld specimen strengths were about 80% of the yield strength of the original cast base metal. The rupture strengths of cross-weld specimens are within 20% of wrought base metal reference data.

36 MATERIALS SCIENCE↗