Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Joining”

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 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Welding investigation of a wrought FeMnAl steel for armor application

A new wrought FeMnAl steel contains high Mn content and high Al content. This steel has high strength. When it is compared to conventional steels with the similar strength, its density is lower. FeMnAl steels can be used in armor vehicle manufacturing, in which welding is a common practice to join the steel plates together. The welding of FeMnAl steels has not been sufficiently studied before. Here, this work studied the weldability and weld microstructure of an FeMnAl steel and provided useful data for the welding practice of FeMnAl steels. The influences of weld filler metals and shielding gases were studied, using single-pass bead-on-plate gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) two processes. The optimal filler metals and shielding gases have been determined to achieve the better weldability. Autogenous GTAW and electron beam welding were also conducted. Cracks were found in the HAZ in the GMAW welds and electron beam welds. Fewer or no cracks were found in the HAZ of GTAW welds. SEM, SEM/EDX, TEM, TEM/EDX, and EBSD were used to analyze the grain boundaries in the HAZ and the cracks. The grain boundaries of FeMnAl base metal are mostly high angle grain boundaries (HAGBs), which attract impurity and solute atoms and cause intergranular cracking. The proposed cracking mechanisms are liquation cracking and ductility-dip cracking. It was found that GTAW provides much better weldability for the FeMnAl steel than GMAW and EBW.

FeMnAl steel↗
DOE OSTI2024

Impact of Backing Plate and Thermal Boundary Conditions for High-Speed Friction Stir Welding of 25-mm Thick Aluminum Alloy 7175-T79

Here this study demonstrates high-speed (150 mm/min) single pass friction stir butt joining of 25 mm thick aluminum alloy 7175-T79. To understand the impact of quenching and cooling rate on process responses, joint strength, and grain size distributions across the weld thickness, we performed a series of friction stir welding (FSW) trials in air and with a trailing water spray using steel and composite backing plates (BP). Welds made in air and trailing water spray exhibit significantly different hardness distributions across the nugget, heat affected zone (HAZ), and HAZ minimum hardness as evidenced by detailed microhardness mapping. The effect of trailing water spray (TWS) on joint efficiency overshadows the influence of BP composition due to the vastly different contribution to quenching. TWS also resulted in a multifaceted effect on FSW such as lowering processing temperature, increasing X and Z forces while lowering Y force, and narrow heat affecting zone. Finally, digital image correlation (DIC)-based fracture mode analysis and grain size measurements correlate with the hardness distribution.

42 ENGINEERING↗
DOE OSTI2021

Quantum-assisted associative adversarial network: applying quantum annealing in deep learning

Abstract Generative models have the capacity to model and generate new examples from a dataset and have an increasingly diverse set of applications driven by commercial and academic interest. In this work, we present an algorithm for learning a latent variable generative model via generative adversarial learning where the canonical uniform noise input is replaced by samples from a graphical model. This graphical model is learned by a Boltzmann machine which learns low-dimensional feature representation of data extracted by the discriminator. A quantum processor can be used to sample from the model to train the Boltzmann machine. This novel hybrid quantum-classical algorithm joins a growing family of algorithms that use a quantum processor sampling subroutine in deep learning, and provides a scalable framework to test the advantages of quantum-assisted learning. For the latent space model, fully connected, symmetric bipartite and Chimera graph topologies are compared on a reduced stochastically binarized MNIST dataset, for both classical and quantum sampling methods. The quantum-assisted associative adversarial network successfully learns a generative model of the MNIST dataset for all topologies. Evaluated using the Fréchet inception distance and inception score, the quantum and classical versions of the algorithm are found to have equivalent performance for learning an implicit generative model of the MNIST dataset. Classical sampling is used to demonstrate the algorithm on the LSUN bedrooms dataset, indicating scalability to larger and color datasets. Though the quantum processor used here is a quantum annealer, the algorithm is general enough such that any quantum processor, such as gate model quantum computers, may be substituted as a sampler.

Wilson, Max (ORCID:0000000207983391)↗
DOE OSTI2020

Effect of 3D printing conditions on the micro- and macrostructure and properties of high-performance thermoplastic composites

Within the scope of extrusion based additive manufacturing, this chapter provides a review of the research in understanding the physical relationships between microstructure variables and macrostructure properties of high-performance thermoplastic polymers. The development of interlayer strength has been discussed based on the theory of inter-diffusion and re-entanglement of polymer chains at interface. The observations from the study in joining and direct-bonding of polymer surfaces provide insights into the mechanisms of the formation of interface between adjacent layers. Quantitative prediction of interfacial strength as a function of processing temperature and contact time is presented. The mechanisms that lead to reduced mechanical strength at the interface are discussed. The second half of the chapter outlined a set of printing conditions and their influence on structural properties.

Liu, Peng↗
DOE OSTI2020

Chapter Nine - Automated Optimal Control in Energy Systems: The Reinforcement Learning Approach

With the development of smart grid technologies an increasing number of new devices and participants have joined modern energy systems and are inevitably making them more complicated and interdependent than ever. Optimally controlling such a complex energy system and maintaining its operation in a high-efficient, secure, and resilient manner are challenging tasks to the system operators. Fortunately, the revolution in deep learning and artificial intelligence (AI), both from hardware and algorithms perspectives, has provided new ideas and solutions to many previously intractable problems. As a result, this advance in computer science also sparked great research interests in utilizing AI in solving engineering problems related to the modern energy systems. Among many AI techniques, deep reinforcement learning (DRL) has demonstrated great potential for solving sequential optimization problems, which are very common in the engineering domains. Its ability to handle nonlinearity and stochasticity in controlled systems has out-competed many traditional optimal control algorithms. Therefore in this chapter, we focus on the state-of-the-art of DRL concepts and related algorithms, compare their pros and cons with traditional optimal control approaches and discuss the typical workflow for leveraging RL in solving complex problems in modern energy systems.

artificial intelligence↗
DOE OSTI2022

An approach to nearest neighbor analysis of pigment-protein complexes using chemical cross-linking in combination with mass spectrometry

Herein, protein cross-linking is the process of chemically joining two amino acids in a protein or protein complex by a covalent bond. When combined with mass spectrometry, it becomes one of the structural mass spectrometry techniques gaining in importance for deriving valuable three-dimensional structural information on proteins and protein complexes. This platform complements existing structural methods, such as NMR spectroscopy, X-ray crystallography, and cryo-EM. Photosynthetic pigment protein complexes serve as light-energy harvesting systems and perform photochemical conversion as part of the “early events” of photosynthesis. This chapter outlines how to prepare cross-linking pigment protein complex samples for LC-MS/MS analysis, including identification of the cross-linked species, network analysis in a protein complex, and structural modeling and justification.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Design of an additively manufactured functionally graded material of 316 stainless steel and Ti-6Al-4V with Ni-20Cr, Cr, and V intermediate compositions

This study presents a method for designing a computationally informed gradient pathway to fabricate a functionally graded material (FGM) with terminal alloys of 316 stainless steel (SS316) and Ti-6Al-4V via directed energy deposition additive manufacturing with powder feedstock. In this work, the grading is accomplished through the introduction of intermediate elements and alloys (Ni-20Cr, Cr, and V) to avoid the brittle Fe-Ti intermetallic phases that form in the direct liquid phase joining of Ti-alloys and stainless steels. Using a combination of equilibrium calculations and Scheil-Gulliver simulations, a compositional pathway was designed to avoid deleterious phases. FGM samples were fabricated and experimentally characterized to determine the viability of the pathway. A change in phases from fcc to bcc was predicted to occur within the Ni-20Cr/Cr gradient region, and this was validated through experimental characterization. No detrimental phases (intermetallic, Laves, or σ phases) formed along the gradient path, demonstrating a successful computationally-informed design and fabrication of an FGM from SS316 to Ti-6Al-4V.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Plasma treatment on both adhesive tape and adherends for significantly enhanced CFRTP-related adhesive joints

Unlike existing literature that primarily concentrates on either the plasma treatment of adherends alone or solely on adhesive surfaces, this work leverages plasma modification of both adhesive in tape form and adherend surfaces to largely enhance the interfacial bonding between a thermoset-based adhesive tape and carbon-fiber-reinforced thermoplastic polymer (CFRTP) for structural bonding applications. Here, by conducting single lap shear tests on adhesively-bonded AA6061-CFRPPA (carbon-fiber-reinforced polyphthalamide) dissimilar joints, it is shown that the plasma treatment of adherends alone can increase the lap shear strength (LSS) of the joints by approximately 200% compared to non-treated counterparts. An additional plasma treatment of adhesive tape surfaces leads to even higher LSS improvement, reaching up to 315%, due to the formation of a denser crosslinked network of covalent bonds and a reduced area fraction of interfacial voids at the CFRPPA/adhesive interface. The highest plasma-enhanced LSS of the metal-CFRTP dissimilar joints rivals that of metal-metal joints, which is typically stronger than the joints associated with fiber-reinforced polymers. This study is important for achieving strong CFRTP-related structural components bonded using adhesive tape, providing better compatibility with plasma treatment and other joining methods like riveting compared to adhesive paste or liquid.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Neutron scattering maps the higher-order assembly of NADPH-dependent assimilatory sulfite reductase

Precursor molecules for biomass incorporation must be imported into cells and made available to the molecular machines that build the cell. Sulfur-containing macromolecules require that sulfur be in its S2- oxidation state before assimilation into amino acids, cofactors, and vitamins that are essential to organisms throughout the biosphere. In α-proteobacteria, NADPH-dependent assimilatory sulfite reductase (SiR) performs the final six-electron reduction of sulfur. SiR is a dodecameric oxidoreductase composed of an octameric flavoprotein reductase (SiRFP) and four hemoprotein metalloenzyme oxidases (SiRHPs). SiR performs the electron transfer reduction reaction to produce sulfide from sulfite through coordinated domain movements and subunit interactions without release of partially reduced intermediates. Efforts to understand the electron transfer mechanism responsible for SiR’s efficiency are confounded by structural heterogeneity arising from intrinsically disordered regions throughout its complex, including the flexible linker joining SiRFP’s flavin-binding domains. As a result, high-resolution structures of SiR dodecamer and its subcomplexes are unknown, leaving a gap in the fundamental understanding of how SiR performs this uniquely large-volume electron transfer reaction. In this work, we use deuterium labeling, in vitro reconstitution, analytical ultracentrifugation (AUC), small-angle neutron scattering (SANS), and neutron contrast variation (NCV) to observe the relative subunit positions within SiR’s higher-order assembly. AUC and SANS reveal SiR to be a flexible dodecamer and confirm the mismatched SiRFP and SiRHP subunit stoichiometry. NCV shows that the complex is asymmetric, with SiRHP on the periphery of the complex and the centers of mass between SiRFP and SiRHP components over 100 Å apart. SiRFP undergoes compaction upon assembly into SiR’s dodecamer and SiRHP adopts multiple positions in the complex. The resulting map of SiR’s higher-order structure supports a cis/trans mechanism for electron transfer between domains of reductase subunits as well as between tightly bound or transiently interacting reductase and oxidase subunits.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Local Decomposition of Hexahedral Singular Nodes into Singular Curves

Hexahedral (hex) meshing is a long studied topic in geometry processing with many challenging associated problems. Hex meshes vary from structured to unstructured depending on application or domain of interest. Fully structured meshes require that all interior mesh edges be adjacent to four hexes each. Edges failing this criteria are singular and indicate an unstructured hex mesh. Singular edges join together into singular curves that either form closed cycles, end on the mesh boundary, or end at a singular node, a complex junction of more than two singular curves. Hex meshes with more complex singular nodes tend to have more distorted elements and smaller scaled Jacobian values. In this work, we study the topology of singular nodes. We show that all eight of the most common singular nodes are decomposable into just singular curves. We further show that all singular nodes, regardless of edge valence, are locally decomposable. Finally we demonstrate these decompositions on hex meshes, thereby decreasing their distortion and converting all singular nodes into singular curves. In conclusion, with this decomposition, the enigmatic complexity of 3D singular nodes becomes effectively 2D.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Enhanced flexibility and thermal conductivity of HfC decorated carbon nanofiber mats

Future-generation spacecraft components allude discovery of novel materials that can withstand extreme environments (>2000 °C). The combined effect of ultra-high temperature ceramics (UHTCs) and carbon fibers (C f ) can satisfy the demanding requirements of aerospace applications. A novel, hybrid, and flexible hafnium carbide (HfC)-decorated carbon nanofiber (C nf ) mat was fabricated via electrospinning. Enhanced thermal stability of the flexible HfC decorated C nf over C nf can be elucidated from the 20-fold increment in thermal conductivity and the onset of degradation at higher temperatures (840 °C). Successful integration of multi-layered sandwich lattice using in-housed fabricated HfC decorated C nf showed retention of the fibrous structure even after extreme spark plasma sintering (SPS) process at 1850 °C. Fabricating a similar multi-layered structure using procured C f was unsuccessful due to bundled agglomeration and micron-sized fibers. High-load indentation suggests that HfC decorated C nf interlayer is stronger (~2.3 times) than the parent UHTC with no cracking at the interface. Compared with the HfC matrix, the indentation-damaged area at the interface reduced up to ~56% due to toughening mechanisms such as C nf , fiber pull-out and bridging. The synthesized HfC decorated Cnf mat is proposed as an ultra-thin filler material for joining similar or dissimilar UHTCs while maintaining similar chemistry and better mechanical integrity at the interface. Furthermore, the findings insinuate a new paradigm in designing hybrid and flexible ceramic-containing materials for thermal protection systems (TPS) of future-generation spacecraft components that can mitigate failure in extreme environments (>2000 °C).

36 MATERIALS SCIENCE↗
DOE OSTI2022

Computational methods in unraveling the mechanism of metallaphotoredox catalysis

Moving from Guangzhou, China to Maryland, USA in 2017 to pursue a Ph.D. in chemistry was terrifying and exciting at the same time. However, it didn’t take me long to commit to working with a young assistant professor. As an undergraduate, I spent countless hours doing the “wet lab” research on green catalysis, where I developed a strong interest in organometallic catalysis and in using mechanistic-driven approach towards the rational design of novel catalytic systems. Not surprisingly, during the group rotation in my first semester in University of Maryland, the research focus and, in particular, the friendly group atmosphere led to my decision to join the research group of Dr. Osvaldo Gutierrez, who was just starting his 2nd year as an assistant professor.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Characterization of microstructure and residual stress following the friction stir welding of dissimilar aluminum alloys

Friction-stir-welding (FSW) has gained importance as an effective way to join dissimilar materials due to its solid-state nature. However, FSW produces substantial residual stresses in aluminum welding, often deteriorating the component's structural performance and reliability. In the current study, the d-spacing (inter-atomic distance) of several locations on a battery tray and stress-free reference samples are measured with neutron diffraction to calculate the residual stresses in a lap 6061 to A365 dissimilar friction-stir-weld. Furthermore, the present study connects the measured residual stress to microstructure properties through electron backscatter diffraction (EBSD) and optical microscopy analyses. The EBSD results indicate that the FSW operation affects the grains’ orientation, thereby producing location-specific directionally varying elasticity across the weldment. Further, this varied elasticity creates unique d-spacing profiles even in the stress-free material. Additionally, the resulting stressed and stress-free d-spacing profiles show dependencies on the FSW tool geometry, traverse direction, and rotational direction. Lastly, this study suggests that the final component residual stress can be influenced by the sequence of multi-pass welds contributing to a rise in temperature in the presence of a completed weld relaxing its residual stress.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A grid-scale study of demand bidding by large industrial users

A demand bidding mechanism for engaging large industrial electricity users in the operation of the power grid is presented. Demand bidding is formulated as an optimization problem based on a modified version of the alternating current optimal power flow problem, and can be interpreted as a tâtonnement process between the grid operator and electricity users. Here, the work provides the first – to the authors’ knowledge – grid-scale case study of demand bidding, using a synthetic grid structure in the footprint of the grid of Texas. Results reveal that the demand bidding lowers overall power generation costs, but economic benefits plateau as the number of participants increases. Transmission line and transformer capacity constraints become the limiting factors, revealing that expanding and fortifying the transmission infrastructure is key to expanding demand-side participation. Demand bidding does not substantially alter the optimal operation of existing bidding entities when the number of bidders increases, thereby supporting existing bidders to stay in the system and encouraging new ones to join.

Chlor-alkali plant↗
DOE OSTI2024

High plasticity in refractory composite fabrication by ultrasonic additive manufacturing

Refractory metal composites are desirable for use in extreme environments that require materials with high specific strengths and resilience to external environments such as that found in nuclear and aerospace. However, due to the high melting temperature of refractories, liquid state joining processes such as welding remains difficult. Ultrasonic additive manufacturing (UAM) provides a potential route for processing refractory composites because it is a solid-state (i.e., no-melting) process and allows for intermittent machining operations to be performed between welds. Further, to demonstrate refractory composite fabrication, this study utilized UAM to machine a cavity to locate and sequester a Mo foil in a Zircaloy-4 (Zry-4) baseplate and additively build over the top with Zry-4 foils, thereby embedding the Mo in Zry-4 matrix. Significant deformation of the Zry-4 microstructure was observed: this deformation caused adiabatic heating and subsequent dynamic recrystallization through the transformation from α→β and then back to α as the material cooled. Flexural testing of the Zr–Mo composite revealed no delamination or failure, but the strength was not as expected, falling lower than a cold-worked Zry-4 sample. Finite element analysis supported that some bonding must have existed between the Zry-4 and Mo. There was indeed an interdiffusion zone at the Zry-4 foil–Mo foil interface, observing a metastable body-centered cubic β-Zr lathe. It was determined that sufficient strain energy was present to encourage the nucleation of the β-Zr grain along α-Zr grains. Future work is warranted to investigate UAM for refractory composite fabrication.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Comparison of interlaminar damage modeling strategies for hybrid composite/aluminum laminates subjected to low-velocity impact

Low-velocity impact of hybrid metal-composite structures was investigated experimentally and computationally. Composite laminates consisting of 2D woven glass fiber reinforced polymer (GFRP) and carbon fiber reinforced polymer (CFRP) were joined with a 6061-T6 aluminum plate using an epoxy adhesive. Two variations of the structure were studied; one consisting of all plies oriented at 0° and one consisting of all plies oriented at 45°. A drop tower was used to impact structures at a range of energies, including energies above and below the threshold at which the aluminum layer was perforated. Numerical simulations were implemented using Sierra/SM, an in-house transient dynamics finite element code developed at Sandia National Laboratories. A Hosford plasticity model was used to describe the response of the aluminum layer. A newly implemented orthotropic continuum damage mechanics (CDM) constitutive model was used to represent the composite laminate. This 3D-CDM model was compared to a cohesive zone model (2D-CDM/CZM) to investigate efficacy of aluminum perforation energy prediction, delamination prediction, and computational cost. Accuracy of each model was evaluated using the experimental results. Each showed good agreement with the tests for both the force and velocity histories, as well as the observed damage mechanisms. The 2D-CDM/CZM model was marginally more accurate in capturing both the composite and aluminum behavior — this model averaged error percentages of -11.2% and 10.8% for residual velocity and peak force, respectively. Meanwhile, the 3D-CDM model predictions yielded average error percentages of -35.5% (velocity) and 22.6% (force). However, the 3D-CDM model generally resulted in a decreased computational cost; the average run time was 14% shorter than the 2D-CDM/CZM model and 3x as many timesteps per hour were computed using the same computational resources. In conclusion, new experimental data on the impact and perforation resistance of metal-composite laminates is presented in addition to numerical predictions of the impact behavior.

Carbon fiber↗
DOE OSTI2024

Testing and modeling of CLT-to-CLT joints made using hardwood dowels and screws with varying spacing

With the increasing popularity of mass timber, utilizing large-diameter wood screws and hardwood dowels can offer an easy and cost-efficient way to join structural elements. However, the existing research on hardwood dowels is limited to single fastener joints under monotonic loading. No research is available on the group effects of joints with multiple hardwood dowels. Here, this paper presents the results of 96 monotonic and cyclic single-shear plane CLT-to-CLT joint tests with hardwood dowels (Red Oak and Yellow Birch, 25.4 mm diameter) and self-tapping wood screws (8 mm diameter) in Grand-Fir CLT, where screws were inserted both perpendicular and at a 45-degree angle to the grain for comparison to hardwood dowels. The study evaluated the mechanical properties of the joints by changing fastener spacing. Mechanical properties such as yielding and peak strength, displacement, elastic and yielding stiffness, and ductility were evaluated. The results showed equal strength and stiffness properties for hardwood dowels comparable with large-diameter screws. Additionally, the hardwood dowel joints demonstrated moderate ductility properties. The strength and stiffness of the tested joints were compared with analytical equations found in the literature by considering the group action factor of the fasteners. Lastly, a nonlinear force-displacement model was presented and compared to the experimental results and analytical calculations, which gives the possibility to predict and optimize the mechanical behavior of hardwood dowel and screw joints with varying numbers and spacing between fasteners.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Genetically pliable green algae for bioproduction of modified fatty acids, nutritional therapeutic oils, and biopharmaceuticals

Homologous recombination (HR) is an essential tool for complex metabolic engineering in yeast, but transgene integration into plant and green algal nuclear genomes predominantly occurs by non-homologous end-joining. Species of the closely related, oleaginous trebouxiophytes Auxenochlorella and Prototheca, are unusual among the green algae in that HR is the favored mechanism for DNA integration into the nuclear genome. This property enables locus-specific targeting of gene cassettes encoding multiple enzymes for manipulating existing biochemical pathways or introducing new functions. Genetic malleability, and regulatory approval for human consumption, coupled with robust fermentation performance at industrial scale, establishes Auxenochlorella and Prototheca as prime candidates for algal production of biochemicals and biomaterials. The examples presented here highlight strain improvement and engineering for synthesis of hydroxylated fatty acids for biomaterials, structured triglycerides resembling human milk fat for infant nutrition, very-long-chain mono- and polyunsaturated fatty acids with nutraceutical or therapeutic potential, and cannabinoids for pharmacological applications.

Moseley, Jeffrey L. [University of California, Ber↗