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At least 73 records · Page 4

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DOE OSTI2025

Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints

A single-class joining process known as “friction self-piercing riveting (F-SPR)” has been developed for joining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting Al Aural 5) with a unified technique. Crack-free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.

Lim, Yong Chae [ORNL] (ORCID:0000000321773988)↗

NASA NTRS1965

Jig and fixture aid fabrication of tungsten rivets

Jig and fixture that holds several lengths of tungsten rods produces rivets simply and inexpensively. The apparatus allows sufficient tungsten to be exposed for heating and forging into a rivet head.

Chattin, J. H.↗

NASA NTRS1982

Oxidation-Strengthened High-Temperature Rivets

Shear strength of titanium-niobium rivets improves with oxidation. Ti-Nb rivets developed for fastening parts of Space Shuttle thrustors may be suitable also for other high-temperature applications in oxidizing environments--for example, in burner cans of commercial jet engines and boilers and retorts for coal gasification systems.

Mclemore, R. L.↗

NASA NTRS1989

Modeling growth of fatigue cracks which originate at rivet holes

When a structural component is subjected to repeated stress cycles, it can fail at stresses which are well below the tensile strength of the material. The processes leading to this failure are termed fatigue. Instances of fatigue failure in aircraft have become an increasing concern. The crack leading to failure often originate at rivet holes and then grow in response to stress cycles which occur during the operation of the aircraft. A necessary step to preventing failures in todays fleet of aging aircraft is to increase the frequency and quality of inspections; steps were already taken in this direction. There is also a need for modeling of fatigue crack growth in the aircraft structures so that improvements in design can be established and predictions of the life of the components can be made. The purpose is to provide a method to accurately predict the growth of fatigue cracks and to use this method to make predictions about the life of aircraft structural components. The method relies on the formulation and numerical solution of a singular integral equation(s) for an arbitrarily shaped crack(s) which propagate in response to the applied loading. Of special interest to the aging aircraft studies are cracks which originate at circular holes (i.e., rivet holes), but other crack geometries can be treated equally as well.

Mear, Mark E.↗

NASA NTRS1991

Thermographic inspection of fatigue cracks in riveted plates

A theoretical and experimental analysis of the inspection of reiveted plates using the thermoelastic effect is presented. Theoretically, a model is employed to estimate the thermoelastic response expected from a cracked and uncracked rivet hole. The stress invariant, which causes the thermoelastic response, is calculated for the cracked case using an FEM model and for the uncracked case using a theoretical approximation. The differences in the two thermal responses are reduced when the effects of optical spatial averaging, thermal conduction, and a concentric blind area representing the rivet heat are considered. It is suggested that discrimination between the cracked and uncracked cases for short cracks will improve with increasing frequency of stress oscillation. Measurements are shown for aerospace aluminum samples with and without fatigue cracks propagating from holes in a plate. The effect of mean stress on the thermoelastic response is illustrated, and the results are qualitatively compared with the finite element analysis.

Welch, Christopher S.↗

NASA NTRS1941

Effect of aging on mechanical properties of aluminum-alloy rivets

Curves and tabular data present the results of strength tests made during and after 2 1/2 years of aging on rivets and rivet wire of 3/16-inch nominal diameter. The specimens were of aluminum alloy: 24S, 17S, and A17S of the duralumin type and 53S of the magnesium-silicide type.

Roop, Frederick C↗

NASA NTRS1956

The fatigue strength of riveted joints and lugs

This report deals with a number of tests on riveted joints and lugs for the primary purpose of comparing the several types of riveted joints and to study the effect of various factors on the fatigue strength of lugs. A check was made to ascertain whether or not an estimate of the fatigue life at a certain loading could be made from the dimensions of the joint and the fatigue data of the unnotched materials. Recommendations are made on the proportioning of joints to obtain better fatigue behavior.

Schijve, J↗

NASA NTRS1940

Mechanical Properties of Flush-Riveted Joints

The strength of representative types of flush-riveted joints has been determined by testing 865 single-shearing, double-shearing, and tensile specimens representing 7 types of rivet and 18 types of joint. The results, presented in graphic form, show the stress at failure, type of failure, and d/t ratio. In general, dimpled joints were appreciably stronger than countersunk or protruding-head joints, but their strength was greatly influenced by constructional details. The optimum d/t ratios have been determined for the several kinds of joints. Photomicrographs of each type show constructional details and, in several instances, cracks in the sheet.

Brueggeman, W C↗

NASA NTRS1941

Effect of aging on mechanical properties of aluminum-alloy rivets

Curves and tabular data present the results of strength tests made during and after 2 1/2 years of aging on rivets and rivet wire of 3/16-inch nominal diameter. The specimens were of aluminum alloy: 24s, 17s, and a17s of the duralumin type and 53s of the magnesium-silicide type.

Roop, Frederick C↗

NASA NTRS1995

Revolving Eddy-Current Probe Detects Cracks Near Rivets

Scanning eddy-current probe in circular pattern increases sensitivity with which probe indicates fatigue cracks and other defects in metal surfaces in vicinity of rivets. Technique devised to facilitate inspection of riveted joints in aircraft. Eddy-current probe in question described in "Electro-magnetic Flaw Detector Is Easier To Use" (LAR-15046).

Namkung, Min↗

NASA NTRS1995

A record of all marker bands found in the upper rivet rows of 2 adjacent bays from a fuselage lap splice joint

A full scale fuselage test article was subjected to 60,000 load cycles (pressurizations) to study the effect of widespread fatigue damage in fuselage structures. Every 10,000 cycles coded marker block loading sequences were used to mark the fracture surfaces of the fatigue cracks propagating within the panel. The loading sequences consisted of series of underloads combined with a series of full pressurizations. The combination of loads and underloads marked the fracture surfaces with marker bands that could later be used to reconstruct the fatigue crack growth history of selected regions within the test article. Thirty rivet holes comprising the upper rivet rows from two adjacent bays (bays #3 and #4) from a fuselage lap splice joint were examined for the purpose of this study. Optical and scanning electron microscopy (SEM) were used to locate the marker bands.

Willard, Scott A.↗

NASA NTRS1997

The Characteristics of Fatigue Damage in the Fuselage Riveted Lap Splice Joint

An extensive data base has been developed to form the physical basis for new analytical methodology to predict the onset of widespread fatigue damage in the fuselage lap splice joint. The results of detailed destructive examinations have been cataloged to describe the physical nature of MSD in the lap splice joint. ne catalog includes a detailed description, e.g., crack initiation, growth rates, size, location, and fracture morphology, of fatigue damage in the fuselage lap splice joint structure. Detailed examinations were conducted on a lap splice joint panel removed from a full scale fuselage test article after completing a 60,000 cycle pressure test. The panel contained a four bay region that exhibited visible outer skin cracks and regions of crack link-up along the upper rivet row. Destructive examinations revealed undetected fatigue damage in the outer skin, inner skin, and tear strap regions. Outer skin fatigue cracks were found to initiate by fretting damage along the faying surface. The cracks grew along the faying surface to a length equivalent to two to three skin thicknesses before penetrating the outboard surface of the outer skin. Analysis of fracture surface marker bands produced during full scale testing revealed that all upper rivet row fatigue cracks contained in a dim bay region grow at similar rates; this important result suggests that fracture mechanics based methods can be used to predict the growth of outer skin fatigue cracks in lap splice structure. Results are presented showing the affects of MSD and out-of-plane pressure loads on outer skin crack link-up.

Piascik, Robert S.↗

NASA NTRS1998

Three-Dimensional Geometric Nonlinear Contact Stress Analysis of Riveted Joints

The problems associated with fatigue were brought into the forefront of research by the explosive decompression and structural failure of the Aloha Airlines Flight 243 in 1988. The structural failure of this airplane has been attributed to debonding and multiple cracking along the longitudinal lap splice riveted joint in the fuselage. This crash created what may be termed as a minor "Structural Integrity Revolution" in the commercial transport industry. Major steps have been taken by the manufacturers, operators and authorities to improve the structural airworthiness of the aging fleet of airplanes. Notwithstanding, this considerable effort there are still outstanding issues and concerns related to the formulation of Widespread Fatigue Damage which is believed to have been a contributing factor in the probable cause of the Aloha accident. The lesson from this accident was that Multiple-Site Damage (MSD) in "aging" aircraft can lead to extensive aircraft damage. A strong candidate in which MSD is highly probable to occur is the riveted lap joint.

Shivakumar, Kunigal N.↗

NASA NTRS2000

A Practical Engineering Approach to Predicting Fatigue Crack Growth in Riveted Lap Joints

An extensive experimental database has been assembled from very detailed teardown examinations of fatigue cracks found in rivet holes of fuselage structural components. Based on this experimental database, a comprehensive analysis methodology was developed to predict the onset of widespread fatigue damage in lap joints of fuselage structure. Several computer codes were developed with specialized capabilities to conduct the various analyses that make up the comprehensive methodology. Over the past several years, the authors have interrogated various aspects of the analysis methods to determine the degree of computational rigor required to produce numerical predictions with acceptable engineering accuracy. This study led to the formulation of a practical engineering approach to predicting fatigue crack growth in riveted lap joints. This paper describes the practical engineering approach and compares predictions with the results from several experimental studies.

Harris, C. E.↗

NASA NTRS2002

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

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

Hoffman, Eric K.↗

NASA NTRS1999

A Practical Engineering Approach to Predicting Fatigue Crack Growth in Riveted Lap Joints

Harris, Charles E.↗

NASA NTRS1940

Mechanical Properties of Flush-Riveted Joints

The strength of representative types of flush-riveted joints has been determined by testing 865 single-shearing, double-shearing, and tensile specimens representing 7 types of rivet and 18 types of joint. The results, presented in graphic form, show the stress at failure, type of failure, and d/t ratio. In general, 'dimpled' joints were appreciably stronger than countersunk or protruding-head joints, but their strength was greatly influenced by constructional details. The optimum d/t ratios have been determined for the several kinds of joints. Photomacrographs of each type show constructional details and, in several instances, cracks in the sheet.

Bruggeman, Wm. C.↗

NASA NTRS1936

Tank Tests of the Effect of Rivet Heads, etc., on the Water Performance of a Seaplane Float, Special Report

A 1/3.5 full-size model of the Mark V float of the Bureau of Aeronautics, Navy Department, was tested in the NACA tank both with smooth painted bottom surfaces and with roundhead rivets, plate laps, and keel plates fitted to simulate the actual bottom of a metal float. The augmentation in water resistance due to the added roughness was found to be from 10-12% at the hum speed and from 12-14% at high speeds. The effect of the roughness of the afterbody was found to be negligible except at high trims. The model data were extrapolated to full size by the usual method which assumes the forces to vary according to Froude's law, and in the case of the smooth model by a method of separation that takes into account the effect of scale on the frictional resistance. It was concluded that the effect of rivet heads on the takeoff performance of a relatively high-powered float seaplane is of little consequence but that it may be of greater importance in the case of more moderately powered flying boats.

Parkinson, J. B.↗