Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “friction stir processing”

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 NTRS2002

Compression Buckling Behavior of Large-Scale Friction Stir Welded and Riveted 2090-T83 Al-Li Alloy Skin-Stiffener Panels

To evaluate the potential of friction stir welding (FSW) as a replacement for traditional rivet fastening for launch vehicle dry bay construction, a large-scale friction stir welded 2090-T83 aluminum-lithium (Al-Li) alloy skin-stiffener panel was designed and fabricated by Lockheed-Martin Space Systems Company - Michoud Operations (LMSS) as part of NASA Space Act Agreement (SAA) 446. The friction stir welded panel and a conventional riveted panel were tested to failure in compression at the NASA Langley Research Center (LaRC). The present paper describes the compression test results, stress analysis, and associated failure behavior of these panels. The test results provide useful data to support future optimization of FSW processes and structural design configurations for launch vehicle dry bay structures.

Hoffman, Eric K.↗
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↗
NASA NTRS2015

Performance Improvement of Friction Stir Welds by Better Surface Finish

The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled.

Russell, Sam↗
NASA NTRS1998

Low-Temperature Friction-Stir Welding of 2024 Aluminum

Solid state friction-stir welding (FSW) has been demonstrated to involve dynamic recrystallization producing ultra-fine, equiaxed grain structures to facilitate superplastic deformation as the welding or joining mechanism. However, the average residual, equiaxed, grain size in the weld zone has ranged from roughly 0.5 micron to slightly more than 10 micron, and the larger weld zone grain sizes have been characterized as residual or static grain growth as a consequence of the temperatures in the weld zone (where center-line temperatures in the FSW of 6061 Al have been shown to be as high as 480C or -0.8 T(sub M) where T(sub M) is the absolute melting temperature)). In addition, the average residual weld zone grain size has been observed to increase near the top of the weld, and to decrease with distance on either side of the weld-zone centerline, an d this corresponds roughly to temperature variations within the weld zone. The residual grain size also generally decreases with decreasing FSW tool rotation speed. These observations are consistent with the general rules for recrystallization where the recrystallized grain size decreases with increasing strain (or deformation) at constant strain rate, or with increasing strain-rate, or with increasing strain rate at constant strain; especially at lower ambient temperatures, (or annealing temperatures). Since the recrystallization temperature also decreases with increasing strain rate, the FSW process is somewhat complicated because the ambient temperature, the frictional heating fraction, and the adiabatic heating fraction )proportional to the product of strain and strain-rate) will all influence both the recrystallization and growth within the FSW zone. Significantly reducing the ambient temperature of the base metal or work pieces to be welded would be expected to reduce the residual weld-zone grain size. The practical consequences of this temperature reduction would be the achievement of low temperature welding. This study compares the residual grain sizes and microstructures in 2024 Al friction-stir welded at room temperature (about 30C and low temperature (-30C).

Benavides, S.↗
DOE OSTI2015

Interfacial microstructure and properties of copper clad steel produced using friction stir welding versus gas metal arc welding

A preliminary study compares the feasibility and microstructures of pure copper claddings produced on a pressure vessel A516 Gr. 70 steel plate, using friction stir welding versus gas metal arc welding. A combination of optical and scanning electron microscopy is used to characterize the grain structures in both the copper cladding and heat affected zone in the steel near the fusion line. The friction stir welding technique produces copper cladding with a grain size of around 25 μm, and no evidence of liquid copper penetration into the steel. The gas metal arc welding of copper cladding exhibits grain sizes over 1 mm, and with surface microcracks as well as penetration of liquid copper up to 50 μm into the steel substrate. Transmission electron microscopy reveals that metallurgical bonding is produced in both processes. Increased diffusion of Mn and Si into the copper cladding occurs when using gas metal arc welding, although some nano-pores were detected in the FSW joint interface. - Highlights: • Cladding of steel with pure copper is possible using either FSW or GMAW. • The FSW yielded a finer grain structure in the copper, with no evidence of cracking. • The FSW joint contains some evidence of nano-pores at the interface of the steel/copper. • Copper cladding by GMAW contained surface cracks attributed to high thermal stresses. • The steel adjacent to the fusion line maintained a hardness value below 248 HV.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Uncovering hidden bias in neutron diffraction residual strain measurements

When calculating residual strain via neutron or X-ray diffraction, uncertainties propagated from the peak fit are often inadequate to describe the true scatter of measurements about a singular strain state, such as one that should describe a macroscopic continuum. Because diffraction is inherently a selective process, orientation-dependent scatter arises from the sub-sampling of strong microstructure and strain gradients. This paper investigates the appropriateness of propagated uncertainties with reference to their original intention, i.e. noise about a mean value. Thirty-six unique orientations of strain measurements are taken at multiple locations within an additive friction-stir deposition component with fine-scale gradients (∼200 µm) of plastic strain, texture and residual elastic strain. Multiple strain and stress calculation pathways are compared: direct substitution of three measurements into Hooke's law, direct inversion of any six unique orientations into the strain state tensor and thirty-six measurement least-squares estimation. For the last two cases, the appropriateness of the uncertainty interval is statistically evaluated on the basis of a physical constraint: common agreement under the strain transformation law. For this sample, the direct inversion of six measurements retains a conservative estimate of the uncertainty. However, propagated uncertainties in the least-squares solution greatly underestimate the true experimental scatter. A simple pathway to estimate appropriate uncertainty intervals is suggested. These results demonstrate that the interpretation of uncertainty in residual strain is strongly dependent on intrinsic sample-dependent effects, and that oversampling orientations and statistical analysis can give more accurate results with realistic uncertainties.

36 MATERIALS SCIENCE↗
NASA NTRS1999

Fundamental Study of Material Flow in Friction Stir Welds

The presented research project consists of two major parts. First, the material flow in solid-state, friction stir, butt-welds as been investigated using a marker insert technique. Changes in material flow due to welding parameter as well as tool geometry variations have been examined for different materials. The method provides a semi-quantitative, three-dimensional view of the material transport in the welded zone. Second, a FSW process model has been developed. The fully coupled model is based on fluid mechanics; the solid-state material transport during welding is treated as a laminar, viscous flow of a non-Newtonian fluid past a rotating circular cylinder. The heat necessary for the material softening is generated by deformation of the material. As a first step, a two-dimensional model, which contains only the pin of the FSW tool, has been created to test the suitability of the modeling approach and to perform parametric studies of the boundary conditions. The material flow visualization experiments agree very well with the predicted flow field. Accordingly, material within the pin diameter is transported only in the rotation direction around the pin. Due to the simplifying assumptions inherent in the 2-D model, other experimental data such as forces on the pin, torque, and weld energy cannot be directly used for validation. However, the 2-D model predicts the same trends as shown in the experiments. The model also predicts a deviation from the "normal" material flow at certain combinations of welding parameters, suggesting a possible mechanism for the occurrence of some typical FSW defects. The next step has been the development of a three-dimensional process model. The simplified FSW tool has been designed as a flat shoulder rotating on the top of the workpiece and a rotating, cylindrical pin, which extends throughout the total height of the flow domain. The thermal boundary conditions at the tool and at the contact area to the backing plate have been varied to fit experimental data such as temperature profiles, torque and tool forces. General aspects of the experimentally visualized material flow pattern are confirmed by the 3-D model.

Reynolds, Anthony P.↗
DOE OSTI2016

Formation mechanisms of periodic longitudinal microstructure and texture patterns in friction stir welded magnesium AZ80

Many studies of friction stir welding have shown that periodicity of metal flow around the tool pin may result in the formation of periodic differences in microstructure and texture in the weld nugget area correlated with the weld pitch. The current work investigates the periodicity of magnesium weld microtexture in the nugget region and its association with material flow using optical and electron microscopy. Two welds created in AZ80 at different processing conditions are presented in detail, one illustrating periodic longitudinal texture change, and one showing for the first time that periodic variations in texture, grain size, or composition are not defining features of periodic nugget flow. While nugget texture is dominated by shear deformation, it was found here to be affected to a lesser degree by compaction of material behind the welding tool, which led to reduction in intensity of the shear texture fiber. The decreased tendency for magnesium based alloys to form periodic patterns as compared to aluminum based alloys is explained with reference to the shear textures. - Highlights: •It is shown here that periodic material flow in the nugget does not necessitate longitudinal texture patterns. •Longitudinal texture patterns are shown to be present or absent in Mg AZ80 based on processing conditions. •Texture in the nugget is mainly dictated by shear deformation, but has measurable effects from other deformation modes. •Explanation of why longitudinal texture change is frequently reported in aluminum but not magnesium alloys is provided. •A new vector visualization of material flow based on EBSD data analysis is shown.

36 MATERIALS SCIENCE↗
NASA NTRS2013

Three Dimensional Numerical Simulation and Characterization of Crack Growth in the Weld Region of a Friction Stir Welded Structure

Friction stir welding (FSW) fabrication technology is being adopted in aerospace applications. The use of this technology can reduce production cost, lead-times, reduce structural weight and need for fasteners and lap joints, which are typically the primary locations of crack initiation and multi-site fatigue damage in aerospace structures. FSW is a solid state welding process that is well-suited for joining aluminum alloy components; however, the process introduces residual stresses (both tensile and compressive) in joined components. The propagation of fatigue cracks in a residual stress field and the resulting redistribution of the residual stress field and its effect on crack closure have to be estimated. To insure the safe insertion of complex integral structures, an accurate understanding of the fatigue crack growth behavior and the complex crack path process must be understood. A life prediction methodology for fatigue crack growth through the weld under the influence of residual stresses in aluminum alloy structures fabricated using FSW will be detailed. The effects and significance of the magnitude of residual stress at a crack tip on the estimated crack tip driving force are highlighted. The location of the crack tip relative to the FSW and the effect of microstructure on fatigue crack growth are considered. A damage tolerant life prediction methodology accounting for microstructural variation in the weld zone and residual stress field will lead to the design of lighter and more reliable aerospace structures

Seshadri, Banavara R.↗
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 OSTI2026

Part-scale evolution of fine-scale microstructural heterogeneity in solid-state additive manufacturing

Current solid-state additive manufacturing methods, refined through costly and time-consuming trial and error, have spurred interest in computational models that replicate material behavior under typical thermomechanical conditions (e.g., strain-rate ~ 102 s−1). These models, however, struggle to capture time-dependent microstructural evolution. In this work, Additive Friction-Stir Deposition (AFSD) is used as a representative case study for part-scale quantification of microstructure evolution at a fine spatial resolution (200 μm) by examining a liquid-nitrogen-cooled stop-action build via energy-dispersive X-ray diffraction coupled with a multi-channel detector. These results inform modeling efforts by linking process asymmetry to stored plastic strain, residual elastic strain, and texture development, and unlike current state-of-the-art characterization methods (e.g., EBSD or neutron diffraction), this approach provides both the spatial resolution and collection efficiency necessary to quantify fine-scale microstructural heterogeneity over large component volumes. As such, this technique provides essential validation data for computational models, e.g., crystal plasticity, enabling future prediction of heterogeneous behavior in AFSD and other additive manufacturing processes.

Franz, Cole [ORNL] (ORCID:0000000213465881)↗
DOE OSTI2018

Microstructure of Friction Stir Welded AlSi9Mg Cast with 5083 and 2017A Wrought Aluminum Alloys

Wrought aluminum alloys 5083 and 2017A were each joined with cast aluminum alloy AlSi9Mg through friction stir welding in butt weld configurations. For each material system, the wrought and cast alloy positions, i.e., the advancing side or the retreating side, were exchanged between welding trials. The produced weldments were free from cracks and discontinuities. For each alloy configuration, a well-defined nugget comprised of alternating bands of the welded alloys characterized the microstructure. The degree of mixing, however, strongly depended on which wrought alloy was present and on its position during processing. In all cases, the cast AlSi9Mg alloy dominated the weld center regardless of its position during welding. Electron backscattered diffraction analysis showed that the grain size in both alloys (bands) constituting the nugget was similar and that the majority of grain boundaries exhibited a high angle character (20°-60°). Regardless of the alloy, however, all grains were elongated along the direction of the material plastic flow during welding. A numerical simulation of the joining process visualized the material flow patterns and temperature distribution and helped to rationalize the microstructural observations. The hardness profiles across the weld reflected the microstructure formed during welding and correlated well with the temperature changes predicted by the numerical model. Tensile specimens consistently fractured in the cast alloy near the weld nugget.

36 MATERIALS SCIENCE↗
NASA NTRS2004

NASA Tech Briefs, December 2004

opics include: High-Rate Digital Receiver Board; Signal Design for Improved Ranging Among Multiple Transceivers; Automated Analysis, Classification, and Display of Waveforms; Fast-Acquisition/Weak-Signal-Tracking GPS Receiver for HEO; Format for Interchange and Display of 3D Terrain Data; Program Analyzes Radar Altimeter Data; Indoor Navigation using Direction Sensor and Beacons; Software Assists in Responding to Anomalous Conditions; Software for Autonomous Spacecraft Maneuvers; WinPlot; Software for Automated Testing of Mission-Control Displays; Nanocarpets for Trapping Microscopic Particles; Precious-Metal Salt Coatings for Detecting Hydrazines; Amplifying Electrochemical Indicators; Better End-Cap Processing for Oxidation-Resistant Polyimides; Carbon-Fiber Brush Heat Exchangers; Solar-Powered Airplane with Cameras and WLAN; A Resonator for Low-Threshold Frequency Conversion; Masked Proportional Routing; Algorithm Determines Wind Speed and Direction from Venturi-Sensor Data; Feature-Identification and Data-Compression Software; Alternative Attitude Commanding and Control for Precise Spacecraft Landing; Inspecting Friction Stir Welding using Electromagnetic Probes; and Helicity in Supercritical O2/H2 and C7H16/N2 Mixing Layers.

Source record↗
NASA NTRS2008

Effect of Weld Tool Geometry on Friction Stir Welded Ti-6Al-4V

In this study, flat 0.250" thick Ti-6Al-4V panels were friction stir welded (FSWed) using weld tools with tapered pins. The five different pin geometries of the weld tools included: 0 degree (straight cylinder), 15 degree, 30 degree, 45 degree, and 60 degree angles on the frustum. All weld tools had a smooth 7 degree concave shoulder and were made from microwave sintered tungsten carbide. For each weld tool geometry, the FSW process parameters were optimized to eliminate internal defects. All the welds were produced in position control with a 2.5 degree lead angle using a butt joint configuration for the panels. The process parameters of spindle rpm and travel speed were varied, altering the hot working conditions imparted to the workpiece. Load cells on the FSWing machine allowed for the torque, the plunge force, and the plow force to be recorded during welding. Resulting mechanical properties were evaluated from tensile tests results of the FSWjoints. Variations in the material flow were investigated by use of microstructural analysis including optical microscopy (OM), scanning electron microscopy (SEM), and orientation image mapping (aIM).

Querin, Joseph A.↗
NASA NTRS2002

Effect of Pin Tool Shape on Metal Flow During Friction Stir Welding

It has been shown that metal moves behind the rotating Friction Stir Pin Tool in two separate currents or streams. One current, mostly on the advancing side, enters a zone of material that rotates with the pin tool for one or more revolutions and eventually is abandoned behind the pin tool in crescent-shaped pieces. The other current, largely on the retreating side of the pin tool is moved by a wiping process to the back of the pin tool and fills in between the pieces of the rotational zone that have been shed by the rotational zone. This process was studied by using a faying surface copper trace to clarify the metal flow. Welds were made with pin tools having various thread pitches. Decreasing the thread pitch causes the large scale top-to-bottorn flow to break up into multiple vortices along the pin and an unthreaded pin tool provides insufficient vertical motion for there to be a stable rotational zone and flow of material via the rotational zone is not possible leading to porosity on the advancing side of the weld.

McClure, J. C.↗
NASA NTRS2006

Comparison of the Effects of Tool Geometry for Friction Stir Welding Thin Sheet Aluminum Alloys for Aerospace Applications

In this presentation, the results of a recent study on the effect of pin tool design for friction stir welding thin sheets (0.040") of aluminum alloys 2024 and 7075 are provided. The objective of this study was to investigate and document the effect of tool shoulder and pin diameter, as well as the presence of pin flutes, on the resultant microstructure and mechanical properties at both room temperature and cryogenic temperature. Specifically, the comparison between three tools will include: FSW process load analysis (tool forces required to fabricate the welds), Static Mechanical Properties (ultimate tensile strength, yield strength, and elongation), and Process window documenting the range of parameters that can be used with the three pin tools investigated. All samples were naturally aged for a period greater than 10 days. Prior research has shown 7075 may require post weld heat treatment. Therefore, an additional pair of room temperature and cryogenic temperature samples was post-weld aged to the 7075-T7 condition prior to mechanical testing.

Merry, Josh↗
DOE OSTI2015

Influence of tool shape on lattice rearrangement under loading conditions reproducing friction stir welding

Metal behavior under loading conditions that reproduce friction stir welding was studied on the atomic scale. Calculations were conducted based on molecular dynamics simulation with potentials calculated within the embedded atom method. The loading of the interface between two crystallites, whose structure corresponded to aluminum alloy 2024, was simulated by the motion of a cone-shaped tool along the interface with constant angular and translational velocities. The motion of the rotating tool causes fracture of the workpiece crystal structure with subsequent mixing of surface atoms of the interfacing crystallites. It is shown that the resistance force acting on the moving tool from the workpiece and the process of structural defect formation in the workpiece depend on the tool shape.

36 MATERIALS SCIENCE↗
NASA NTRS2006

Effects of Laser and Shot Peening on Fatigue Crack Growth in Friction Stir Welds

The effects of laser, and shot peening on the fatigue life of Friction Stir Welds (FSW) have been investigated. The surface roughness resulting from various peening techniques was assessed, and the fracture surfaces microstructure was characterized. Laser peening resulted in an increase in fatigue life approximately 60%, while shot peening resulted in 10% increase when compared to the unpeened material. The surface roughness of shot peening was significantly higher compared to the base material, while specimens processed with laser peening were relatively smooth.

Hatamleh, Omar↗