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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Friction Stir Welding – an Advanced Approach to Repair Nuclear Power Plant Components

Solid phase joining technique friction stir welding (FSW) has been shown to mitigate helium-related issues in fusion welding of irradiated steels. Here, we present detailed characterization results of the first friction stir weld of an irradiated 304L stainless steel (SS) coupon contained 5.2 atomic parts per million (appm) helium. Scanning electron microscopy (SEM) was used to characterize a cross section specimen removed from the friction stir weld. No macro helium induced crack was observed at the analyzed cross-section, and only 1 – 1.5 µm size pores were found in the stir zone (SZ) and the thermal-mechanical affected zone (TMAZ). Moreover, some minor helium aggregations (Maximum ~20 µm in length) appeared along grain boundaries inside the TMAZ. Thereafter, miniature tensile specimens were extracted from the SZ, TMAZ and heat affected zone (HAZ), and base metal (BM) and tested. All welded specimens showed high total elongations (> 60%) and strengths (> 75% BM strengths). Overall, the weld made by FSW showed much better results comparing with traditional fusion welding on irradiated SS.

Tang, Wei↗
DOE OSTI2022

Low friction wear resistant graphene films

A low friction wear surface with a coefficient of friction in the superlubric regime including graphene and nanoparticles on the wear surface is provided, and methods of producing the low friction wear surface are also provided. A long lifetime wear-resistant surface including graphene exposed to hydrogen is provided, including methods of increasing the lifetime of graphene containing wear surfaces by providing hydrogen to the wear surface.

Sumant, Anirudha V.↗
DOE OSTI2018

Mechanical Properties and Wear Behavior of AA5182/WC Nanocomposite Fabricated by Friction Stir Welding at Different Tool Traverse Speeds

Grain growth inhibition at the heat-affected zone, improved weld strength and superior tribological properties of welds are desirable attributes of modern manufacturing. With the focused on these attributes, tungsten carbide (WC) nanoparticles were employed as reinforcements for the friction stir welding of 5-mm-thick AA5182 aluminum alloy by varying tool traverse speeds. The microstructure, microhardness, ultimate tensile strength, fracture and wear behavior of the resultant WC-reinforced welds were investigated, while unreinforced AA5182 welds were employed as controls for the study. The result shows that the addition of WC nanoparticles causes substantial grain refinement within the weld nugget. A decrease in traverse speed caused additional particle fragmentation, improved hardness value and enhanced weld strength in the reinforced welds. Improved wear rate and friction coefficient of welds were attained at a reduced traverse speed of 100 mm/min in the WC-reinforced welds. This improvement is attributed to the effects of reduced grain size/grain fragmentation and homogeneous dispersion of WC nanoparticles within the WC-reinforced weld nugget.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Manufacturing of magnesium/aluminum bimetallic ring components by friction stir assisted simultaneous forging and solid-state joining

Here, a bimetallic ring component is forged by a friction stir assisted forging (FS-forging). A cylindrical bimetallic blank, magnesium AZ31 cylinder (Mg core) tightly fitted inside an aluminum 6061-T6 tube (Al skin), is used. In the FS-forging, the frictional heat and stirring of rotating tool forge the blank into a desired shape, while simultaneously generate a solid-state joint between the Mg core and the Al skin, without additional external heating, as confirmed by the microstructural analysis and mechanical tests. The microstructural analysis also shows that the characteristics of the solid-state joint can be different depending on the process parameters.

42 ENGINEERING↗
DOE OSTI2014

Impact of higher-order flows in the moment equations on Pfirsch-Schlüter friction coefficients

The impact of the higher-order flows in the moment approach on an estimate of the friction coefficients is numerically examined. The higher-order flows are described by the lower-order hydrodynamic flows using the collisional plasma assumption. Their effects have not been consistently taken into account thus far in the widely used neoclassical transport codes based on the moment equations in terms of the Pfirsch-Schlüter flux. Due to numerically solving the friction-flow matrix without using the small-mass ratio expansion, it is clearly revealed that incorporating the higher-order flow effects is of importance especially for plasmas including multiple hydrogenic ions and other lighter species with similar masses.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2014

Frictional interactions at high velocity ductile metal interfaces

We have examined the effect of evolution of grain morphology on the frictional force at polycrystalline Al-Al and Al-Ta interfaces as a function of grain size and sliding velocity. We present the results of 8M, 26M and 138M particle NonEquilibrium Molecular Dynamics (NEMD) simulations for grain sizes of 13 and 20 nm. Sample sizes consisted of 3×3×3 and 5×5×5 grains on each side of a sliding interface. We have considered sliding velocities from 20 to 4000 m/s. For velocities below a size dependent critical velocity above which a fluid layer forms, we find enhanced grain coarsening leading to a highly strained, graded final steady state microstructure that exhibits a dynamic morphology for times greater than 5-10 ns. We find that the frictional force is insensitive to the initial grain size distribution due to the evolution of the initial distribution to a new nonequilibrium steady state. We discuss the relationship of these results to single crystal interfaces and the mechanisms for grain size and shape evolution.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Constraints on Friction, Dilatancy, Diffusivity, and Effective Stress From Low-Frequency Earthquake Rates on the Deep San Andreas Fault

Families of recurring low-frequency earthquakes (LFEs) within nonvolcanic tremor on the San Andreas Fault in central California are sensitive to tidal stresses. LFEs occur at all levels of the tides, are strongly correlated and in phase with the ~200 Pa shear stresses, and weakly and not systematically correlated with the ~2 kPa tidal normal stresses. Here, we assume that LFEs are small sources that repeatedly fail during shear within a much larger scale, aseismically slipping fault zone and consider two different models of the fault slip: (1) modulation of the fault slip rate by the tidal stresses or (2) episodic slip, triggered by the tides. LFEs are strongly clustered with duration much shorter than the semidiurnal tide; they cannot be significantly modulated on that time scale. The recurrence times of clusters, however, are many times longer than the semidiurnal, leading to an appearance of tidal triggering. In this context we examine the predictions of laboratory-observed triggered frictional (dilatant) fault slip. The undrained end-member model produces no sensitivity to the tidal normal stress, and slip onsets are in phase with the tidal shear stress. The tidal correlation constrains the diffusivity to be less than ~1 × 10 -6 /s and the product of the friction and dilatancy coefficients to be at most 5 × 10 -7 , orders of magnitude smaller than observed at room temperature. In the absence of dilatancy the effective normal stress at failure would be about ~55 kPa. Finally, for this model the observations require intrinsic weakness, low dilatancy, and lithostatic pore fluid.

58 GEOSCIENCES↗
DOE OSTI2019

Joining AA7099 to Ni-Cr-Mo Steel using Friction Stir Dovetailing

Friction stir dovetailing (FSD) was used to join 0.5 inch (12.7 mm) AA7099 to 0.5 inch (12.7 mm) Ni-Cr-Mo steel in a lap configuration. Two new FSD approaches are reported that significantly reduce zinc embrittlement of Fe-Al intermetallic compounds (IMCs) which form during conventional friction stir welding (FSW). The first method uses the general FSD approach where a custom designed tool is employed to extrude the AA7099 into the pre-machined dovetail groove of underlying steel by forming mechanical interlocking and metallurgical bonding simultaneously. The second method uses a two-step approach where FSD of AA6061 is first used to form a silicon-rich Fe-Al IMC within the dovetail groove. AA7099 plate is then joined to the AA6061 within the dovetail using conventional FSW. A discussion of the new FSD technique, joint configurations, and process parameters are provided along with joint microstructural analyses and mechanical performance.

Friction stir dovetailing, FSD, AA7099, AA6061, ro↗
DOE OSTI2023

Extent of interlocking and metallurgical bonding in friction riveting of aluminum alloy to steel

In this study, the joining of 6061-T6 aluminum alloy and DP590 steel using a M42 steel rivet via friction riveting technique is investigated. The surface morphology and microstructure characterization reveal the formation of an anchor zone that imparts mechanical interlock as well as the formation of metallurgical bonds at the interface of aluminum and steel. A combination of interlocking and bonding results in the achievement of a high load-carrying capacity of 5.7 kN during lap shear testing at room temperature. A finite element-based computational model was developed which accurately predicted the lap shear response of the joint. The model revealed that the metallurgical bond formed during fric-riveting adds 39% peak load strength to the joint. An extensive microstructural investigation, post-lap-shear fractography, and the modeling results, together provided insights on the joint failure mechanism. In conclusion, this study highlights that friction riveting is a promising method for aluminum-to-steel dissimilar joining, which is important for lighweighing automotive vehicles for energy efficiency.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Towards High-Speed friction stir welding of 25 mm Thick AA2139-T8: tool innovation and process development

Joining thick plates (≥ 12 mm) of aluminum (Al) alloys is challenging due to high tool forces, uneven material flow, and non-uniform heat distribution through the material’s thickness. Recent advancements in tool design and welding parameters for friction stir welding (FSW) in thick plates butt joining have encountered a developmental plateau, highlighting the need for innovative approaches to overcome existing limitations. Here, this study focuses on the systematic development of single-pass and double-pass FSW processes for high-strength aluminum alloy AA2139-T8, to improve joint efficiency and enable high-speed welding capabilities. Experimental evidence is presented for a novel tool design with opposing pin threads, enabling high-speed (178 mm/min) single-pass friction stir butt welding of 25 mm thick AA2139-T8. A series of FSW trials was conducted both in air and with a trailing water spray, using steel backing plates (BPs) to investigate the impact of quenching and cooling rates on process response and joint performance. A joint efficiency of 83% was attained using the novel tool features and effectively controlling process forces and thermal boundary conditions.

AA2139-T8↗
DOE OSTI2017

Numerical Modeling Describing the Effects of Heterogeneous Distributions of Asperities on the Quasi-static Evolution of Frictional Slip

A better understanding of how slip accumulates along faults and its relation to the breakdown of shear stress is beneficial to many engineering disciplines, such as, hydraulic fracture and understanding induced seismicity (among others). Asperities forming along a preexisting fault resist the relative motion of the two sides of the interface and occur due to the interaction of the surface topographies. We employ a finite element model to simulate circular partial slip asperities along a nominally flat frictional interface. Shear behavior of our partial slip asperity model closely matched the theory described by Cattaneo. The asperity model was employed to simulate a small section of an experimental fault formed between two bodies of polymethyl methacrylate, which consisted of multiple asperities whose location and sizes were directly measured using a pressure sensitive film. The quasi-static shear behavior of the interface was modeled for cyclical loading conditions, and the frictional dissipation (hysteresis) was normal stress dependent. We further our understanding by synthetically modeling lognormal size distributions of asperities that were randomly distributed in space. Synthetic distributions conserved the real contact area and aspects of the size distributions from the experimental case, allowing us to compare the constitutive behaviors based solely on spacing effects. Traction-slip behavior of the experimental interface appears to be considerably affected by spatial clustering of asperities that was not present in the randomly spaced, synthetic asperity distributions. Finally, estimates of bulk interfacial shear stiffness were determined from the constitutive traction-slip behavior and were comparable to the theoretical estimates of multi-contact interfaces with non-interacting asperities.

58 GEOSCIENCES↗
DOE OSTI2021

Microstructural evolution in Cu-Nb processed via friction consolidation

Immiscible alloys, whether in well-mixed or layered forms, are of increasing interest based on their novel structural and functional properties, such as enhanced thermal stability against grain growth or radiation-induced defect trapping at the interfaces. To address the need for new approaches to tailor microstructures, the microstructural development of an immiscible Cu-Nb alloy processed via friction consolidation of elemental powders is investigated. Friction consolidation is a solid-phase processing technique that imparts severe plastic strain into a deforming volume resulting in elevated temperatures below the melting temperature of the alloy. Two distinct processing pathways were chosen to understand the effect of thermomechanical conditions on the final microstructure. The microstructure was characterized using scanning electron microscopy, scanning transmission electron microscopy, and X-ray diffraction techniques. Path 1 exhibited larger strain, strain rate, and temperature as compared with path 2. In path 1, agglomerated Nb particles were present in the recrystallized ultrafine-grained Cu matrix, while in path 2 extremely fine and dispersed Nb particles were present in a highly deformed Cu matrix. In both pathways, supersaturation of Cu in Nb lattices was noted, but not vice-versa. The asymmetry in mixing is explained based on deformation-based, thermodynamic and kinetic factors. These findings provide a pathway for creation of novel tailored microstructures and improved properties in any number of binary immiscible alloy systems.

Cu-Nb alloys, Microstructural refinement, Friction↗
DOE OSTI2017

Advanced Process Possibilities in Friction Crush Welding of Aluminum, Steel, and Copper by Using an Additional Wire

Joining sheet metal can be problematic using traditional friction welding techniques. Friction crush welding (FCW) offers a high speed process which requires a simple edge preparation and can be applied to out-of-plane geometries. In this work, an implementation of FCW was employed using an additional wire to weld sheets of EN AW5754 H22, DC01, and Cu-DHP. The joint is formed by bringing together two sheet metal parts, introducing a wire into the weld zone and employing a rotating disk which is subject to an external force. The requirements of the welding preparation and the fundamental process variables are shown. Thermal measurements were taken which give evidence about the maximum temperature in the welding center and the temperature in the periphery of the sheet metals being joined. The high welding speed along with a relatively low heat input results in a minimal distortion of the sheet metal and marginal metallurgical changes in the parent material. In the steel specimens, this FCW implementation produces a fine grain microstructure, enhancing mechanical properties in the region of the weld. Aluminum and copper produced mean bond strengths of 77 and 69 pct to that of the parent material, respectively, whilst the steel demonstrated a strength of 98 pct. Using a wire offers the opportunity to use a higher-alloyed additional material and to precisely adjust the additional material volume appropriate for a given material alignment and thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Friction Hydro-Pillar Processing of a High Carbon Steel: Joint Structure and Properties

A coupled experimental and theoretical study is reported here on friction hydro-pillar processing of AISI 4140 steel, which is a novel solid-state joining technique to repair and fill crack holes in thick-walled components by an external stud. The stud is rotated and forced to fill a crack hole by plastic flow. During the process, frictional heating occurs along the interface of the stud and the wall of crack hole leading to thermal softening of the stud that eases its plastic deformation. The effect of the stud force, its rotational speed and the total processing time on the rate of heat generation and resulting transient temperature field is therefore examined to correlate the processing variables with the joint structure and properties in a systematic and quantitative manner, which is currently scarce in the published literature. The results show that a gentler stud force rate and greater processing time can promote proper filling of the crack hole and facilitate a defect-free joint between the stud and original component.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Nanostructured Fe-20Cr-10Ni-2Si Layer Produced by Laser Cladding and Friction Stir Processing

Laser cladding of Fe-20Cr-10Ni-2Si alloy usually faces challenge of metallurgical defects like micropores and interdendritic fragile precipitates. In this paper, the laser cladding combined with friction stir processing (FSP) was applied to deal with this problem and prepare the nanostructured Fe-20Cr-10Ni-2Si alloy layer. The coarse dendritic grains (5 ~ 10 μm) of laser processed Fe-20Cr-10Ni-2Si alloy were broken into nanocrystallines which contain uniformly distributed nanoparticles (5 ~ 400 nm) in the deformation zone by FSP. The gradient microstructure with an average grain size of several nanometers on the top surface to several micrometers in the center part was obtained by FSP. Meanwhile, the grain size in the plastic zone decreases as the rotary speed rises. Grain refinement by FSP results in the increase of microhardness from 323 HV up to 583 HV, decreasing the friction coefficient from 0.42 to 0.35 and thus the wear resistance is improved.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Fabrication of AZ31/MWCNTs Surface Metal Matrix Composites by Friction Stir Processing: Investigation of Microstructure and Mechanical Properties

The surface metal matrix composites of AZ31 Mg alloy reinforced with multiwall carbon nanotubes (MWCNTs) have been fabricated through the friction stir processing by a conventional and two stepped tools. The microstructure and mechanical properties of fabricated composites were studied by optical and electron microscopy, microhardness and tensile tests, respectively. The processing has developed a fine-grain structure along with good distribution of reinforcements. The hardness and tensile strength of fabricated MWCNT/AZ31 composites are generally higher than as-received and FSPed samples. The accumulative effect of grain refinement and reinforcing nanotubes is assumed to be the reason for increasing the ductility after friction stir processing. The hardness is nearly doubled for FSPed samples and some more for nanocomposites compared with the as-received sample. The elongation of nanocomposites is about two times greater than that of the as-rolled sample. The speed ratio, pass number and CNT amount are three important factors influencing the resulting microstructure and mechanical properties. The stepped tools also give a more uniform distribution of reinforcement and higher grain refinement.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The Simulation of Precipitation Evolutions and Mechanical Properties in Friction Stir Welding with Post-Weld Heat Treatments

A finite element model of friction stir welding capable of re-meshing is used to simulate the temperature variations. Re-meshing of the finite element model is used to maintain a fine mesh resolving the gradients of the solution. The Kampmann–Wagner numerical model for precipitation is then used to study the relation between friction stir welds with post-weld heat treatment (PWHT) and the changes in mechanical properties. Results indicate that the PWHT holding time and PWHT holding temperature need to be optimally designed to obtain FSW with better mechanical properties. Higher precipitate number with lower precipitate sizes gives higher strength in the stirring zone after PWHT. The coarsening of precipitates in HAZ are the main reason to hinder the improvement of mechanical property when PWHT is used.

36 MATERIALS SCIENCE↗