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At least 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Formation of Al/(Al{sub 13}Fe{sub 4} + Al{sub 2}O{sub 3}) Nano-composites via Mechanical Alloying and Friction Stir Processing

Combination of mechanical alloying and friction stir processing was used for the fabrication of Al/(Al{sub 13}Fe{sub 4} + Al{sub 2}O{sub 3}) nano-composites. Pre-milled hematite + Al powder mixture was introduced into the stir zone generated on 1050 aluminum alloy sheet by friction stir processing. Uniform and active milled powder mixture reacted with plasticized aluminum to produced Al{sub 13}Fe{sub 4} + Al{sub 2}O{sub 3} particles. Al{sub 13}Fe{sub 4} intermetallic showed elliptical shape with a typical size of ~ 100 nm, while nano-sized Al{sub 2}O{sub 3} exhibited irregular floc-shaped particles that formed clusters with the remnant of iron oxide particles in the fine recrystallized aluminum matrix. As the milling time (1-3 h) of the introduced powder mixture increased, the volume fraction of Al{sub 13}Fe{sub 4} + Al{sub 2}O{sub 3} particles increased in the fabricated composite. The hardness and ultimate tensile strength of the fabricated nano-composites varied from 54.5 to 75 HV and 139 to 159 MPa, respectively; these are much higher than those of the friction stir processed base alloy (33 HV and 97 UTS). The highest hardness and strength were achieved for the nano-composite fabricated using the 3-h milled powder mixture; hard nano-sized reaction products and fine recrystallized grains of Al matrix had major and minor roles on enhancing these properties, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Micro-Arc Oxidation on Friction–Wear Behavior of Cold-Sprayed Al Coating in 3.5 wt.% NaCl Solution

A cold-sprayed Al coating on S355 steel was processed using micro-arc oxidation (MAO). The friction–wear behavior of the obtained coating in 3.5 wt.% NaCl solution was investigated using a wear test, and the effects of wear loads and speeds on the friction–wear performances of the MAO coating were analyzed. The results show that the MAO coating is primarily composed of Al{sub 2}O{sub 3}, with no other phases. The average coefficients of friction (COFs) of the MAO coating under the wear loads of 0.5, 1.0 and 1.5 N are 0.48, 0.62, and 0.76, respectively, and the corresponding wear rates are 4.20 × 10{sup −5}, 4.21 × 10{sup −5} and 4.27 × 10{sup −5} mm{sup 3} m{sup −1} N{sup −1}, exhibiting the higher wear resistance. Under the wear load of 1.0 N, the average COFs of the MAO coating at the wear speeds of 5.0, 6.7 and 8.3 Hz are 0.32, 0.45 and 0.62, respectively; and the corresponding wear rates are 3.21 × 10{sup −5}, 3.49 × 10{sup −5} and 4.21 × 10{sup −5} mm{sup 3} m N{sup −1}, respectively, which increase with the increase in wear speeds. The wear mechanism of the MAO coating is fatigue wear and abrasive wear, and its wear resistance was better than the cold-sprayed Al coating.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer

A novel single pass friction stir dovetailing (FSD) was developed to join thick plate AA7099 to Ni-Cr-Mo steel in a lap configuration through the use of an AA6061 butter layer. The butter layer approach can be shown to significantly reduce interfacial failures by inhibiting the formation of brittle Fe–Al intermetallic compounds (IMCs) which are typically formed during conventional friction stir welding (FSW) of AA7099 directly to steel. This study evaluates the strength and microstructural evolution of the aluminum/steel joint interface between single pass FSD of AA7099/AA6061(butter)/steel fabricated using three different FSD tool configurations. The butter layer was achieved by placement of a free-floating strip of AA6061 within the dovetail groove that was pre-machined in the steel substrate. Friction stir welding was then used to simultaneously join the thick plate AA7099, the AA6061 strip and the AA7099 in a single weld pass. To optimize the joining process, three different pin geometries (full thread, half smooth/half thread, no thread) were evaluated; it was demonstrated that the half smooth/half thread tool produced the strongest weld joint due to the absence of a Zn rich layer at the Al/steel interface. The efficacy of this unique processing technique was tested using lap shear tensile testing as well as high resolution transmission electron microscopy (TEM). A discussion of the new FSD technique, joint configurations, and process parameters are provided along with joint microstructural analyses and mechanical performance.

Olszta, Matthew J.↗
DOE OSTI2023

Friction Extrusion: Solid-State Metal Synthesis and Recycling in Sustainable Manufacturing

Friction extrusion (FE) is a novel solid-state process for synthesis and recycling of metals and alloys. The novelty of FE is that it utilizes the frictional heating and extensive plastic deformation intrinsic in the process to stir, mechanically alloy, consolidate, and convert powders, chips, and other recyclable feedstock metals into a usable product form of highly engineered materials. FE represents a potentially transformational sustainable manufacturing technology. Being a solid-state process, it eliminates the energy-intensive melting and solidification steps, which are necessary in the conventional metal recycle and synthesis processes. Therefore, FE is a highly energy-efficient, practically zero-emission, and economically competitive process. Here, in this work, the concept and configuration of FE are introduced, the energy-saving advantage of FE is analyzed, the feasibility of FE is demonstrated with synthesizing Al alloys, and the results of some metallographic and mechanical properties studies are presented. A prognosis of the friction extrusion technology is outlined.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A new apparatus for the concurrent measurement of friction and permeability evolution in fault gouge

Here we introduce a new miniature double direct shear (mini-DDS) apparatus, housed within a standard-triaxial (TEMCO) pressure vessel, capable of concurrently measuring the evolution of frictional strength, stability, healing and along-fault permeability under in situ conditions of stress and temperature. The apparatus accommodates gouge samples (25 mm × 32 mm) and intact rock samples with confining and shear stresses and pore pressures up to ~26 MPa. Permeability may be measured with applied flow rates ranging from 1.67 × 10 -11 to 3.6 × 10 -6 m 3 /s to a flow accuracy of 0.5% representing a lower bound of permeability >2.2 × 10 -18 m 2 . Sliding velocities are in the range 0.1 μm/s to 0.67 cm/s with a frame stiffness of 0.067 kN/μm. We describe protocols and procedures for calibration and experiments and note the potential of the apparatus for both rapid and extended-duration measurements of friction-permeability evolution and healing. The apparatus returns measurements of friction and stability of reference materials of F110 quartz consistent with the literature while additionally allowing the concurrent measurement of permeability. Permeability of F110 quartz evolves in slide-hold-slide (SHS) experiments with increases during holds and decreases during subsequent slides. These observations are consistent with grain crushing and resultant wear products that reduce that permeability by clogging during slides with unclogging of the major fluid channels occurring during shearing.

58 GEOSCIENCES↗
DOE OSTI2018

Investigation of temperature dependent microstructure evolution of pure iron during friction stir welding using liquid CO2 rapid cooling

Highlights: • Microstructure evolution during the FSW of pure iron was investigated under low and high heat input conditions, respectively. • Rapid cooling, tool stop action, marker insert and short-time annealing were employed to clarify the microstructure evolution. • Continuous and discontinuous dynamic recrystallizations occur during the microstructure evolution under both the conditions. • Incomplete and complete recrystallized microstructures were developed severally under the low and high heat input conditions. • Grain growth occurs during the normal cooling stage but it is very limited under the low heat input condition. - Abstract: The microstructure evolution of pure iron during friction stir welding was reconstructed by an ingenious experimental design, in which the rapid cooling friction stir welding combined with the tool “stop action” technique and the subsequent short-time annealing were adopted to “freeze” the transient microstructure during the stirring and reproduce the normal cooling during conventional friction stir welding, respectively. The microstructure evolution during the stirring and normal cooling was investigated along the material flow path and in the annealed “frozen” weld zone by high-resolution electron-backscatter-diffraction technique. The results show that the continuous and discontinuous dynamic recrystallizations occur simultaneously at the severe deformation stage in front of the tool both under low and high heat input conditions. However, during the material flow, the microstructure evolution involves the plastic deformation, recrystallization, high angle boundaries migration and dynamic recovery under the low heat input condition, while in a dynamic balance of deformation, recrystallization and grain growth under the high heat input conditions. At the cooling stage, normal grain growth occurs both for the low and high heat input welding conditions, while it is very limited for the low heat input condition.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Friction stir welding of a carbon-doped CoCrFeNiMn high-entropy alloy

Highlights: • Friction stir welding of a CoCrFeNiMn HEA doped with C was successfully obtained. • M{sub 23}C{sub 6} carbides with d≈150 nm form in the HEA due to addition of 0.9 at.% C. • Friction stir welding resulted in a decrease in grain size from 9.2 μm to 4.6 μm. • Smaller grain size and increased fraction of M{sub 23}C{sub 6} increase strength by 84 MPa. - Abstract: Butt-joint seam of a high entropy alloy (HEA) of the CoCrFeNiMn system was successfully obtained by friction stir welding (FSW). The HEA was produced by self-propagating high-temperature synthesis. Along with the principal elements, a small amount (0.9 at.%) of C was added to the alloy. The as-cast alloy was cold rolled and annealed at 900 °C to produce refined microstructure. The structure of the annealed alloy consisted of a recrystallized face-centered cubic matrix with a grain size of 9.2 μm and fine Cr-rich M{sub 23}C{sub 6} carbides. FSW of the HEA resulted in microstructure refinement to d = 4.6 μm in the stir zone. A noticeable rise in strength and some decrease in ductility of the processed alloy in comparison with the initial condition can be associated with the microstructure refinement and some increase in the volume fraction of M{sub 23}C{sub 6} carbides.

36 MATERIALS SCIENCE↗
DOE OSTI2018

What is the effect of lipophilic polymeric ionic liquids on friction and wear?

In this work, methacrylate-type ionic liquid (IL) monomers containing a quaternary ammonium cation and two different counter-anions were synthesized and used as co-monomers to obtain functional poly(alkyl methacrylates) (PAMAs) as friction and wear reducing additives for lubricants. The effect of molecular weight, polymer topology (random or diblock), and IL counter anion on friction and wear behavior of polymer PAO (poly-alpha olefin) solutions have been investigated. The results were compared to those of PAO solutions additized with a small molecule, non-polymeric ionic liquid, or non-ionic copolymers containing 2-(dimethylamino)ethyl methacrylate (DMAEMA) as the polar comonomer. No clear correlation between polymer molecular weight and friction or wear behavior was observed. Random ionic liquid copolymers led to lower wear volumes than their block counterparts. Polymers containing dicyanamide (DCA) counter anion showed lower wear volume compared to those containing bis((trifluoromethyl)sulfonyl)imide (TFSI) anion. Surprisingly, none of the IL copolymers studied outperformed the DMAEMA containing block copolymer in terms of wear volume reduction, suggesting the IL moiety had no beneficial effect on wear.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Evaluation and optimization of flow boiling frictional pressure drop correlations using the data from traditional and next-generation refrigerants in a micro-fin tube

This study presents an experimental evaluation and optimization of flow boiling frictional pressure drop correlations for conventional and next-generation refrigerants in a horizontal micro-fin tube, with particular emphasis on the newly emerging refrigerant blends R-454C and R-455A, for which pressure-drop data in enhanced tubes remain limited. Experiments were conducted with R-410A, R-454C, R-455A, R-134a, R-1234yf, and R-1234ze(E) in a copper micro-fin tube with an inner diameter of 8.468 mm, over mass fluxes ranging from 100 to 300 kg/(m²·s) depending on the refrigerant, and evaporation temperatures of 7, 12, and 14 °C. Frictional pressure gradients were determined from measured total pressure drops after subtracting acceleration pressure drop, and the resulting database was used to assess four existing models: Kuo and Wang (1996), Cavallini et al. (1997), Goto et al. (2001), and Diani et al. (2014). The measured frictional pressure gradient increased with vapor quality and mass flux for all refrigerants and increased further at lower evaporation temperatures, with the overall trend strongly related to liquid viscosity. Among the four correlations, the Goto et al. (2001) model provided the best overall agreement with the measured data before optimization. To further improve prediction accuracy, the Kuo and Wang (1996) and Goto et al. (2001) models were optimized using the complete experimental database. After optimization, both models reduced the overall mean absolute deviation to below 15%, while the optimized Goto et al. (2001) model maintained the best and most consistent overall performance. The results provide new pressure-drop data for next-generation refrigerants and demonstrate that parameter optimization can significantly enhance the applicability of existing micro-fin-tube correlations.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗
DOE OSTI2018

Compatibility between Various Ionic Liquids and an Organic Friction Modifier as Lubricant Additives

Tribological performance of a boundary lubrication contact is largely dominated by the friction modifier (FM) and antiwear (AW) additives in the lubricant. While oil-soluble ionic liquids (ILs) have recently demonstrated promising AW functionality, their compatibility with FMs is little known and even less understood for nonferrous alloys. Here in this paper, we report the latest results for several selected ILs when used together with an organic FM (OFM) in lubricating a steel–bronze contact. Depending on the IL chemistry, either synergistic or antagonistic effects were observed. The three aprotic ILs ([P 8888 ][DEHP], [P 66614 ][BTMPP], and [P 66614 ][C 17 H 35 COO]) seemed to degrade the OFM’s lubricating performance. In contrast, the protic IL [N 888 H][DEHP] exhibited a strong synergistic effect with the OFM, yielding an ultralow steady-state friction coefficient (0.02) and a low wear rate (<10 –8 mm 3 /(N m)), which significantly outperformed the IL or the OFM alone. Surface characterization found no chemically reacted tribofilm on the bronze worn surface. On the other hand, a unique physically adsorbed surface film as a result of interconnection between the IL and OFM molecules by hydrogen bonds is proposed on the basis of chemical analysis. Such an adsorption surface film is expected to be difficult to compress vertically but easy to shear horizontally, leading to low friction and wear.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Alkyl-Cyclens as Effective Sulfur- and Phosphorus-Free Friction Modifiers for Boundary Lubrication

Modern automotive engines operate at higher power densities than ever before, driving a need for new lubricant additives capable of reducing friction and wear further than ever before while not poisoning the catalytic converter. Reported in this paper is a new class of molecular friction modifier (FM), represented by 1,4,7,10-tetradodecyl-1,4,7,10-tetraazacyclododecane (1a), designed to employ thermally stable, sulfur- and phosphorus-free alkyl-substituted nitrogen heterocycles with multiple nitrogen centers per molecule. The multiple nitrogen centers enable cooperative binding to a surface which provides strong surface adsorption and lubricant film durability in the boundary lubrication (BL) regime. A 1 wt % loading of the cyclen FM 1a in Group III base oil exhibits strong surface adsorption, leading to excellent reductions in friction (70%) and wear (95%) versus the pure Group III oil across a wide temperature range. The lubricant with the new FM additive also outperforms two commercially available noncyclic amine-based FMs and a fully formulated commercial 5W30 motor oil.

Desanker, Michael↗
DOE OSTI2018

Friction-Stability-Permeability Evolution of a Fracture in Granite

The evolution of frictional strength, stability, and fracture permeability is intimately linked both to the seismic cycle and to the impact of hydraulic stimulation for fractured reservoirs. However, despite this importance, the poromechanical relationships between fault permeability and strength remain unclear. The present study explores this relationship via laboratory experiments for concurrent shear-flow on smooth fractures of Westerly granite. The novelty of these experiments is that the shear velocity is precisely controlled during the measurement of fracture permeability. Results indicate permeability enhancement during velocity-weakening (potentially unstable) frictional slip. To decipher key processes contributing to this response, we evaluate the state of contacting asperities and of fracture surface asperities via digital rock fracture modeling of statistically equivalent surfaces. We propose two plausible mechanisms constraining the relationship between friction and permeability evolution—one based on changes in asperity contact distribution and one on shear-induced dilation triggered by changes in fault slip velocity. Finally, these mechanisms should be taken into account in interpreting field observation such as the abrupt permeability increase of natural faults at the onset of seismic slip.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

Collapse of Reacted Fracture Surface Decreases Permeability and Frictional Strength

Abstract Geochemical and geomechanical perturbations of the subsurface caused by the injection of fluids present risks of leakage and seismicity. This study investigated how acidic fluid flow affects hydraulic and frictional properties of fractures using experiments with 3.8‐cm‐long specimens of Eagle Ford shale, a laminated shale with carbonate‐rich strata. In low‐pressure flow cells, one set of samples was exposed to acidic brine and another set was exposed to neutral brine. X‐ray computed tomography and energy‐dispersive X‐ray spectroscopy revealed that samples exposed to acidic brine were calcite‐depleted and had developed a porous altered layer, while the other set showed no evidence of alteration. After reaction, samples were compressed and sheared in a triaxial cell that supplied normal stress and differential pore pressure at prescribed sliding velocities, independently measuring friction and permeability. During the initial compression, the porous altered layer collapsed into fine particles that filled the fracture. This effectively impeded flow and sealed the fracture, resulting in fracture permeability to decrease 1 to 2 orders of magnitude relative to the unaltered fractures. This is a favorable outcome in subsurface applications where the goal is to reduce leakage risks. However, during shear the reacted fracture had lower frictional strength because the fine‐grained particles in the collapsed layer prevented the formation of interlocking microasperities. Therefore, coupled geochemical and geomechanical processes that could favorably seal fractures could also increase the likelihood of induced seismicity. These findings have important implications for geological carbon sequestration, pressurized fluid energy storage, geothermal energy, and other subsurface technologies.

58 GEOSCIENCES↗
DOE OSTI2023

The Role of Clay in Limiting Frictional Healing in Fault Gouges

Abstract Frictional healing is fundamental to the seismic cycle and plays a role in the energy balance, dynamics, and recurrence interval of earthquakes and slow slip events. Although the healing behavior of quartz has been studied extensively, the role of clay content is less understood. We tested synthetic mixtures of quartz and smectite (10%–100% smectite) in a double‐direct shear configuration to measure frictional healing. We show that the magnitude and rate of healing decreases systematically with higher clay content (from 0.008/decade at 10% smectite to 0.002/decade at 100% smectite). Healing scales with both the magnitude of stress relaxation during holds and layer‐normal compaction of the gouge. We suggest this reflects the alignment of clay minerals, leading to saturation of the real area of contact that limits restrengthening during holds. The low healing rates of clay‐rich faults—together with rate‐neutral to rate‐strengthening friction—should promote frequent, small failures or stable sliding.

58 GEOSCIENCES↗
DOE OSTI2018

Roles of sliding-induced defects and dissociated water molecules on low friction of graphene

Sliding contact experiments and first-principles calculations were performed to elucidate the roles of structural defects and water dissociative adsorption process on the tribo-chemical mechanisms responsible for low friction of graphene. Sliding friction tests conducted in ambient air and under a dry N2 atmosphere showed that in both cases a high running-in coefficient of friction (COF) occurred initially but a low steady-state COF was reached only when the sliding was continued in air with moisture. Density functional theory (DFT) calculations indicated that the energy barrier ( E B ) for dissociative adsorption of H 2 O was significantly lower in case of reconstructed graphene with a monovacancy compared to pristine graphene. Cross-sectional transmission electron microscopy of graphene transferred to the counterface revealed a partly amorphous structure incorporating damaged graphene layers with d-spacings larger than that of the original layers. DFT calculations on the reconstructed bilayer AB graphene systems revealed an increase of d-spacing due to the chemisorption of H, O, and OH at the vacancy sites and a reduction in the interlayer binding energy ( E B ) between the bilayer graphene interfaces compared to pristine graphene. Thus, sliding induced defects facilitated dissociative adsorption of water molecules and reduced COF of graphene for sliding tests under ambient and humid environments but not under an inert atmosphere.

Science & Technology - Other Topics↗
DOE OSTI2020

Transition between protein-like and polymer-like dynamic behavior: Internal friction in unfolded apomyoglobin depends on denaturing conditions

Equilibrium dynamics of different folding intermediates and denatured states is strongly connected to the exploration of the conformational space on the nanosecond time scale and might have implications in understanding protein folding. For the first time, the same protein system apomyoglobin has been investigated using neutron spin-echo spectroscopy in different states: native-like, partially folded (molten globule) and completely unfolded, following two different unfolding paths: using acid or guanidinium chloride (GdmCl). While the internal dynamics of the native-like state can be understood using normal mode analysis based on high resolution structural information of myoglobin, for the unfolded and even for the molten globule states, models from polymer science are employed. The Zimm model accurately describes the slowly-relaxing, expanded GdmCl-denaturated state, ignoring the individuality of the different aminoacid side chain. The dynamics of the acid unfolded and molten globule state are similar in the framework of the Zimm model with internal friction, where the chains still interact and hinder each other: the first Zimm relaxation time is as large as the internal friction time. Transient formation of secondary structure elements in the acid unfolded and presence of α-helices in the molten globule state lead to internal friction to a similar extent.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Hot-electron effects during reactive scattering of H 2 from Ag(111): the interplay between mode-specific electronic friction and the potential energy landscape

The breakdown of the Born–Oppenheimer approximation gives rise to nonadiabatic effects in gas-surface reactions at metal surfaces. However, for a given reaction, it remains unclear which factors quantitatively determine whether these effects measurably contribute to surface reactivity in catalysis and photo/electrochemistry. Here, we systematically investigate hot electron effects during H 2 scattering from Ag(111) using electronic friction theory. We combine first-principles calculations of tensorial friction by time-dependent perturbation theory based on density functional theory and an analytical neural network representation, to overcome the limitations of existing approximations and explicitly simulate mode-specific nonadiabatic energy loss during molecular dynamics. Despite sizable hot-electron-induced energy loss, no measurable nonadiabatic effects can be found for H 2 scattering on Ag(111). This is in stark contrast to previous reports for vibrationally excited H 2 scattering on Cu(111). By detailed analysis of the two systems, we attribute this discrepancy to a subtle interplay between the magnitude of electronic friction along intramolecular vibration and the shape of the potential energy landscape that controls the molecular velocity at impact. On the basis of this characterization, we offer guidance for the search of highly nonadiabatic surface reactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Friction stir scribe welding technique for dissimilar joining of aluminium and galvanised steel

Friction stir scribe technology, a derivative of friction stir welding, was applied for the dissimilar lap welding of an aluminum alloy and galvanized mild steel sheets. During the process, the rotating tool with a cobalt steel scribe first penetrated the top material — aluminum — and then the scribe cut the bottom material — steel. The steel was displaced into the upper material to produce a characteristic hook feature. Lap welds were shear tested, and their fracture paths were studied. Welding parameters affected the welding features including hook height, which turned out to be highly related to fracture position. Therefore, in this paper, the relationships among welding parameters, hook height, joint strength and fracture position are presented. In addition, influence of zinc coating on joint strength was also studied. Keywords: friction stir scribe technology; dissimilar material welding; zinc coating; hook height; joint strength; fracture position

Aluminum↗