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NASA NTRS2008

Gimballed Shoulders for Friction Stir Welding

In a proposed improvement of tooling for friction stir welding, gimballed shoulders would supplant shoulders that, heretofore, have been fixedly aligned with pins. The proposal is especially relevant to self-reacting friction stir welding. Some definitions of terms, recapitulated from related prior NASA Tech Briefs articles, are prerequisite to a meaningful description of the proposed improvement. In friction stir welding, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a pin that rotates with the shoulder and protrudes from the shoulder into the depth of the workpiece. In conventional friction stir welding, the main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional friction stir welding is augmented with an auto-adjustable pin-tool (APT) capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or forcecontrol system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding as practiced heretofore, there are two shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. Both shoulders rotate with the pin and remain aligned coaxially with the pin. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft into the friction-stir-welding machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. This concludes the prerequisite definitions of terms.

Carter, Robert↗

NASA NTRS2006

Advances in Measurement of Skin Friction in Airflow

The surface interferometric skin-friction (SISF) measurement system is an instrument for determining the distribution of surface shear stress (skin friction) on a wind-tunnel model. The SISF system utilizes the established oil-film interference method, along with advanced image-data-processing techniques and mathematical models that express the relationship between interferograms and skin friction, to determine the distribution of skin friction over an observed region of the surface of a model during a single wind-tunnel test. In the oil-film interference method, a wind-tunnel model is coated with a thin film of oil of known viscosity and is illuminated with quasi-monochromatic, collimated light, typically from a mercury lamp. The light reflected from the outer surface of the oil film interferes with the light reflected from the oil-covered surface of the model. In the present version of the oil-film interference method, a camera captures an image of the illuminated model and the image in the camera is modulated by the interference pattern. The interference pattern depends on the oil-thickness distribution on the observed surface, and this distribution can be extracted through analysis of the image acquired by the camera. The oil-film technique is augmented by a tracer technique for observing the streamline pattern. To make the streamlines visible, small dots of fluorescentchalk/oil mixture are placed on the model just before a test. During the test, the chalk particles are embedded in the oil flow and produce chalk streaks that mark the streamlines. The instantaneous rate of thinning of the oil film at a given position on the surface of the model can be expressed as a function of the instantaneous thickness, the skin-friction distribution on the surface, and the streamline pattern on the surface; the functional relationship is expressed by a mathematical model that is nonlinear in the oil-film thickness and is known simply as the thin-oil-film equation. From the image data acquired as described, the time-dependent oil-thickness distribution and streamline pattern are extracted and by inversion of the thin-oil-film equation it is then possible to determine the skin-friction distribution. In addition to a quasi-monochromatic light source, the SISF system includes a beam splitter and two video cameras equipped with filters for observing the same area on a model in different wavelength ranges, plus a frame grabber and a computer for digitizing the video images and processing the image data. One video camera acquires the interference pattern in a narrow wavelength range of the quasi-monochromatic source. The other video camera acquires the streamline image of fluorescence from the chalk in a nearby but wider wavelength range. The interference- pattern and fluorescence images are digitized, and the resulting data are processed by an algorithm that inverts the thin-oil-film equation to find the skin-friction distribution.

Brown, James L.↗

NASA NTRS1960

Measurements of Skin Friction of the Compressible Turbulent Boundary Layer on a Cone with Foreign Gas Injection

Measurements of average skin friction of the turbulent boundary layer have been made on a 15deg total included angle cone with foreign gas injection. Measurements of total skin-friction drag were obtained at free-stream Mach numbers of 0.3, 0.7, 3.5, and 4.7 and within a Reynolds number range from 0.9 x 10(exp 6) to 5.9 x 10(exp 6) with injection of helium, air, and Freon-12 (CCl2F2) through the porous wall. Substantial reductions in skin friction are realized with gas injection within the range of Mach numbers of this test. The relative reduction in skin friction is in accordance with theory-that is, the light gases are most effective when compared on a mass flow basis. There is a marked effect of Mach number on the reduction of average skin friction; this effect is not shown by the available theories. Limited transition location measurements indicate that the boundary layer does not fully trip with gas injection but that the transition point approaches a forward limit with increasing injection. The variation of the skin-friction coefficient, for the lower injection rates with natural transition, is dependent on the flow Reynolds number and type of injected gas; and at the high injection rates the skin friction is in fair agreement with the turbulent boundary layer results.

Pappas, Constantine C.↗

NASA NTRSDate not supplied

Skin Friction Measurement on a Swept NACA 0015 Wing Using Oil Film Interferometry

An application of oil film interferometry (OFI) to measure skin friction on the 3D flow over an NACA 0015 airfoil with 30° of sweep is presented. Local flow direction must be known to apply OFI to complex 3D flows such as this. A recently developed surface flow vector extraction method was integrated into the OFI analysis algorithm. Surface flow vectors were used to calculate the surface streamlines and hence provided local flow direction to the OFI analysis. After calibration using photogrammetry, the surface flow vectors also enabled decomposition of the skin friction coefficient into different components (such as chordwise and spanwise). The presented method successfully measured skin friction at locations with different flow characteristics such as high skin friction regions, strong spanwise flow regions, and 3D flow separated regions. In the current OFI analysis, multiple interferogram images acquired at different times were analyzed for the same location. The multiple interferogram analysis enabled averaging, which reduced the scatter the skin friction data. The results presented herein demonstrate the capability of the current approach, thereby extending OFI skin friction measurements to complex 3D flows.

Skin friction measurement↗

NASA NTRSDate not supplied

Skin Friction Measurement on a Swept NACA 0015 Wing Using Oil Film Interferometry

Skin friction measurement↗

NASA NTRS1971

Exploratory study of friction welds in Udimet 700 and TD-Nickel bar

Friction welded butt joints were made in both Udimet 700 and TD-Nickel bar. Also, dissimilar metal friction welds were made between these materials. Friction welding of Udimet 700 shows great promise because the welds were found to be as strong as the parent metal in stress rupture and tensile tests at 760 and 980 C. The weld line was not detectable metallographically in the heat treated condition. Friction welding for TD-Nickel, however, holds little if any promise. TD-Nickel friction weldments could support only 9 percent as much stress as the base metal for a 10-hour stress-rupture life at 1090 C. Dissimilar Udimet 700/TD-Nickel friction welds could sustain only 15 percent as much stress as the TD-Nickel parent metal for a 10-hour rupture life at 930 C.

Moore, T. J.↗

NASA NTRS1974

Friction behavior of 304 stainless steel of varying hardness lubricated with benzene and some benzyl structures

The lubricating properties of some benzyl and benzene structures were determined by using 304 stainless steel surfaces strained to various hardness. Friction coefficients and wear track widths were measured with a Bowden-Leben type friction apparatus by using a pin-on-disk specimen configuration. Results obtained indicate that benzyl monosulfide, dibenzyl disulfide, and benzyl alcohol resulted in the lowest friction coefficients for 304 stainless steel, while benzyl ether provided the least surface protection and gave the highest friction. Strainhardening of the 304 stainless steel prior to sliding resulted in reduced friction in dry sliding. With benzyl monosulfide, dibenzyl disulfide, and benzyl alcohol changes in 304 stainless steel hardness had no effect upon friction behavior.

Buckley, D. H.↗

NASA NTRS1975

Large Space Telescope oscillations induced by CMG friction

Conditions are predicted under which limit cycles may be caused by the friction torque of the control moment gyroscope (CMG) output gimbal used in the Large Space Telescope (LST). The parameter plane analysis technique is described, and three separate models of the CMG output friction nonlinearity are used in three separate analyses. The results suggest that the Dahl model (included in model 3) is the best available friction model for use in dynamic analysis. The analysis and analog simulation indicate the absence of limit cycle behavior due to the CMG output gimbal friction nonlinearity for presently estimated LST numerical parameters and the occurrence of one stable and one unstable limit cycle if substantially larger numerical values are allowed for the CMG gimbal pivot friction parameter and/or the running friction torque.

Seltzer, S. M.↗

NASA NTRS1976

Effect of adsorbed films on friction of Al2O3-metal systems

The kinetic friction of polycrystalline Al2O3 sliding on Cu, Ni, and Fe in ultrahigh vacuum was studied as a function of the surface chemistry of the metal. Clean metal surfaces were exposed to O2, Cl2, C2H4, and C2H3Cl, and the change in friction due to the adsorbed species was observed. Auger electron spectroscopy assessed the elemental composition of the metal surface. It was found that the systems exposed to Cl2 exhibited low friction, interpreted as the van der Waals force between the Al2O3 and metal chloride. The generation of metal oxide by oxygen exposures resulted in an increase in friction, interpreted as due to strong interfacial bonds established by reaction of metal oxide with Al2O3 to form the complex oxide (spinel). The only effect of C2H4 was to increase the friction of the Fe system, but C2H3Cl exposures decreases friction in both Ni and Fe systems, indicating the dominance of the chlorine over the ethylene complex on the surface

Pepper, S. V.↗

NASA NTRS1977

Friction and wear properties of three hard refractory coatings applied by radiofrequency sputtering

The adherence, friction, and wear properties of thin hard refractory compound coatings applied to 440C bearing steel by radiofrequency sputtering were investigated. Friction and wear tests were done with nonconforming pin on disk specimens. The compounds examined were chromium carbide, molybdenum silicide, and titanium carbide. The adherence, friction, and wear were markedly improved by the application of a bias voltage to the bearing steel substrate during coating deposition. Analysis by X-ray photoelectron spectroscopy indicated that the improvement may be due to a reduction in impurities in bias deposited coatings. A fivefold reduction in oxygen concentration in MoSi2 coating by biasing was noted. Chromium carbide was not effective as an antiwear coating. Molybdenum silicide provided some reduction in both friction and wear. Titanium carbide exhibited excellent friction and antiwear properties at light loads. Plastic flow and transfer of the coating material onto the pin specimen appears to be important in achieving low friction and wear.

Brainard, W. A.↗

NASA NTRS1979

Friction and wear of single-crystal manganese-zinc ferrite

Sliding friction experiments were conducted with single crystal manganese-zinc ferrite in contact with itself and with transition metals. Results indicate mating highest atomic density directions (110) on matched crystallographic planes exhibit the lowest coefficient of friction, indicating that direction is important in the friction behavior of ferrite. Matched parallel high atomic density planes and crystallographic directions at the interface exhibit low coefficients of friction. The coefficients of friction for ferrite in contact with various metals are related to the relative chemical activity of these metals. The more active the metal, the higher the coefficient of friction. Cracking and the formation of hexagon- and rectangular-shaped platelet wear debris due to cleavages of (110) planes are observed on the ferrite surfaces as a result of sliding.

Miyoshi, K.↗

NASA NTRS1979

Friction and wear of single-crystal manganese-zinc ferrite

Sliding friction experiments were conducted with single-crystal manganese-zinc ferrite in contact with itself and with transition metals. Results indicate mating highest atomic density directions (110 line type) on matched crystallographic planes exhibit the lowest coefficient of friction indicating that direction is important in the friction behavior of ferrite. Matched parallel high atomic density planes and crystallographic directions at the interface exhibit low coefficients of friction. The coefficients of friction for ferrite in contact with various metals are related to the relative chemical activity of these metals. The more active the metal, the higher the coefficient of friction. Cracking and the formation of hexagon- and rectangular-shaped platelet wear debris due to cleavages are observed on the ferrite surfaces as a result of sliding.

Miyoshi, K.↗

NASA NTRS1980

Friction evaluation of unpaved, gypsum-surface runways at Northrup Strip, White Sands Missile Range, in support of Space Shuttle Orbiter landing and retrieval operations

Friction measurement results obtained on the gypsum surface runways at Northrup Strip, White Sands Missile Range, N. M., using an instrumented tire test vehicle and a diagonal braked vehicle, are presented. These runways were prepared to serve as backup landing and retrieval sites to the primary sites located at Dryden Flight Research Center for shuttle orbiter during initial test flights. Similar friction data obtained on paved and other unpaved surfaces was shown for comparison and to indicate that the friction capability measured on the dry gypsum surface runways is sufficient for operations with the shuttle orbiter and the Boeing 747 aircraft. Based on these ground vehicle friction measurements, estimates of shuttle orbiter and aircraft tire friction performance are presented and discussed. General observations concerning the gypsum surface characteristics are also included and several recommendations are made for improving and maintaining adequate surface friction capabilities prior to the first shuttle orbiter landing.

Yager, T. J.↗

NASA NTRS1981

Surface chemistry and friction behavior of the silicon carbide (0001) surface at temperatures to 1500 deg C

X-ray photoelectron and Auger electron spectroscopy analyses and friction studies were conducted with a silicon carbide (0001) surface in contact with iron at various temperatures to 1200 or 1500 C in a vacuum of 10 to the minus 8th power Pa. The results indicate that there is a significant temperature influence on both the surface chemistry and friction properties of silicon carbide. The principal contaminant of adsorbed amorphous carbon on the silicon carbide surface in the as received state is removed by simply heating to 400 C. Above 400 C, graphite and carbide type carbine are the primary species on the silicon carbide surface, in addition to silicon. The coefficients of friction of polycrystalline iron sliding against a single crystal silicon carbide (0001) surface were high at temperatures to 800 C. Similar coefficients of friction were obtained at room temperature after the silicon carbide was preheated at various temperatures up 800 C. When the friction experiments were conducted above 800 C or when the specimens were preheated to above 800 C, the coefficients of friction were dramatically lower. At 800 C the silicon and carbide type carbon are at a maximum intensity in the XPS spectra. With increasing temperature above 800 C, the concentration of the graphite increases rapidly on the surface, whereas those of the carbide type carbon and silicon decrease rapidly.

Miyoshi, K.↗

NASA NTRS1982

Friction and wear of iron and nickel in sodium hydroxide solutions

A loaded spherical aluminum oxider rider was made to slide, while in various solutions, on a flat iron or nickel surface reciprocate a distance of 1 cm. Time of experiments was 1 hr during which the rider passed over the rider passed over the center section of the track 540 times. Coefficients of friction were measured throughout the experiments. Wear was measured by scanning the track with a profilometer. Analysis of some of the wear tracks included use of the SEM (scanning electron microscrope) and XPS (X-ray photoelectron spectroscopy). Investigated were the effect of various concentractions of NaOH and of water. On iron, increasing NaOH concentration above 0.01 N caused the friction and wear to decrease. This decrease is accompanied by a decrease in surface concentration of ferric oxide (Fe2O3) while more complex iron-oxygen compounds, not clearly identified, also form. At low concentrations of NaOH, such as 0.01 N, where the friction is high, the wear track is badely torn up and the surface is broken. At high concentration, such as 10 N, where the friction is low, the wear track is smooth. The general conclusion is that NaOH forms a protective, low friction film on iron which is destroyed by wear at low concentrations but remains intact at high concentrations of NaOH. Nickel behaves differently than iron in that only a little NaOH gives a low coefficient of friction and a surface which, although roughened in the wear track, remains intact.

Rengstorff, G. W. P.↗

NASA NTRS1983

Friction and wear of some ferrous-base metallic glasses

Sliding friction experiments, X-ray photoelectron spectroscopy (XPS) analysis, and electron microscopy and diffraction studies were conducted with ferrous base metallic glasses (amorphous alloys) in contact with aluminum oxide at temperatures to 750 C in a vacuum. Sliding friction experiments were also conducted in argon and air atmospheres. The results of the investigation indicate that the coefficient of friction increases with increasing temperature to 350 C in vacuum. The increase in friction is due to an increase in adhesion resulting from surface segregation of boric oxide and/or silicon oxide to the surface of the foil. Above 500 C the coefficient of friction decreased rapidly. The decrease correlates with the segregation of boron nitride to the surface. Contaminants can come from the bulk of the material to the surface upon heating and impart boric oxide and/or silicon oxide at 350 C and boron nitride above 500 C. The segregation of contaminants is responsible for the friction behavior. The amorphous alloys have superior wear resistance to crystalline 304 stainless steel. The relative concentrations of the various constituents at the surfaces of the amorphous alloys are very different from the nominal bulk compositions.

Miyoshi, K.↗

NASA NTRS1983

Friction and wear of iron and nickel in sodium hydroxide solutions

A loaded spherical aluminum oxider rider was made to slide, while in various solutions, on a flat iron or nickel surface reciprocate a distance of 1 cm. Time of experiments was 1 hr during which the rider passed over the center section of the track 540 times. Coeficients of friction were measured throughout the experiments. Wear was measured by scanning the track with a profilometer. Analysis of some of the wear tracks included use of the SEM (scanning electron microscope) and XPS (X-ray photoelectron spectroscopy). Investigated were the effect of various concentrations of NaOH and of water. On iron, increasing NaOH concentration above 0.01 N caused the friction and wear to decrease. This decrease is accompanied by a decrease in surface concentration of ferric oxide (Fe2O3) while more complex iron-oxygen compounds, not clearly identified, also form. At low concentrations of NaOH, such as 0.01 N, where the friction is high, the wear track is badly torn up and the surface is broken. At high concentration, such as 10 N, where the friction is low, the wear track is smooth. The general conclusion is that NaOH forms a protective, low friction film on iron which is destroyed by wear at low concentrations but remains intact at high conentrations of NaOH. Nickel behaves differently than iron in that only a little NaOH gives a low coefficient of friction and a surface which, although roughened in the wear track, remains intact. Previously announced in STAR as N83-10171

Rengstorff, G. P.↗

NASA NTRS1984

Effects of water-vapor on friction and deformation of polymeric magnetic media in contact with a ceramic oxide

The effects of humidity (water-vapor) in nitrogen on the friction and deformation behavior of magnetic tape in contact with a Ni-Zn ferrite spherical pin were studied. The coefficient of friction is markedly dependent on the ambient relative humidity. In elastic contacts the coefficient of friction increased linearly with increasing humidity; it decreased linearly when humidity was lowered. This effect is the result of changes in the chemistry and interaction of tape materials such as degradation of the lubricant. In plastic contacts there was no effect of humidity on friction below 40 percent relative humidity. There is no effect on friction associated with the breakthrough of the adsorbed water-vapor film at the interface of the tape and Ni-Zn ferrite. The coefficient of friction, however, increased rapidly with increasing relative humidity above 40 percent in plastic contacts.

Miyoshi, K.↗