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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Formation of gradient microstructure and mechanical properties of hot-pressed W-20 wt% Cu composites after sliding friction severe deformation

Highlights: • W particles of composites were refined during sliding friction treatment (SFD). • Dislocation, dislocation tangles and boundary clearly exist in deformed W particle. • YS and UTS of SFDed sample are 308.74 MPa and 553.60 MPa owing to the refinement. • Electrical conductivity of SFDed sample decreased from 33 IACS% to 28.5 IACS%. • Fracture mode changing from inter-granular mode to trans-granular. - Abstract: W-based alloys are currently considered promising candidates for high heat flux components in future fusion reactors. In this paper, hot pressed W-20 wt%Cu composites were treated at room temperature using a sliding friction severe deformation (SFD) process, with a moving speed of 0.2 m/s and an applied load of 500 N. Microstructural evolution of composites after the SFD treatment was evaluated and compared with that of the untreated composites. Results showed that there was a gradient structure generated and an obvious refinement in tungsten particles size in the surface layer after the SFD process. The average particle size of tungsten in the SFD treated composites was 2.60 μm, whereas it was 4.5 μm for tungsten in the untreated composites. Fracture surfaces of the composites indicated that the SFD treatment destroyed the W skeleton and changed fracture mode from predominant inter-granular one to trans-granular one due to the decrease in contact area of W-W inter-particles. Yield strength and ultimate tensile strength of composites after the SFD treatment were 308 MPa and 553 MPa, respectively. The treated composites exhibited micro-hardness values with an average reading of about 308 HV. Analysis of the facture microstructures clearly suggested that the tungsten particles in the treated composites are consisted of dislocations and boundaries as well as dislocation tangles. The electrical conductivity of the composites was decreased from 33 IACS% to 28.5 IACS% after the SFD treatment, mainly due to loss or squeezing of copper into the inner surface.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Multi-scale and multi-technic microstructure analysis of a linear friction weld of the metastable-β titanium alloy Ti-5Al-2Sn-2Zr-4Mo-4Cr (Ti17) towards a new Post-Weld Heat Treatment

Highlights: • Soft joint showing sharp macro-zones and marked by asymmetrical process effects • Gradient of thermomechanical loads identified through progressive stages of transformation • Highly textured recrystallized β grains at the joint core with distorted β lattice • Lattices, phase fractions, microstructures and hardness homogenized after heat treatment - Abstract: Linear Friction Welding (LFW) is a solid-state joining process producing narrow joints mainly developed for the aircraft industry. The Thermo-Mechanical Processing (TMP) loads imposed on the material cause complex microstructure transformations. This study aimed at characterizing the local microstructures and crystallographic configurations to identify the mechanisms impacting the stability and the mechanical properties of a Ti17 LFW joint with the objective of establishing an innovative homogenizing Post-Weld Heat Treatment (PWHT). The process caused a narrow zone of ±2 mm from the friction interface to reach the isothermal α → β transformation temperature under a heating rate of 500 K/s followed by quenching (−100 K/s). The TMP resulted in the formation a ±3 mm wide soft Process Affected Zone (PAZ) delimited by three characteristic zones: the Welding Line (WL width ≈ 400 μm), The Thermo-Mechanically Affected Zone (TMAZ width ≈ 1 mm) and the Heat Affected Zone (HAZ). β TMP resulted in the total dissolution of the α phase in the joint core (WL + TMAZ) and formed strongly textured {110}<111> β recrystallized grains in the WL by continuous dynamic recrystallization of squeezed prior-β grains in the TMAZ. α + β TMP led to a gradual loss of hardness in the HAZ whose microstructure is similar to the one of the base material (BM) but is subject to gradual α laths dissolution due to the local temperatures experienced during LFW. A PWHT consisting in a β annealing followed by an α + β ageing resulted in a uniformly hardened weld with a homogenized Widmanstätten microstructure in the whole assembly.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A comparative research on bobbin tool and conventional friction stir welding of Al-Mg-Si alloy plates

Highlights: • 6061-T4 Al plates were successfully welded by both BT-FSW and C-FSW processes. • A wide welding parameter window was achieved with bobbin tool. • BT-FSW joints showed good strength similar to that of C-FSW joints. • Proving that an Isothermal Dissolution Layer Theory also apply to BT-FSW - Abstract: In our work, Al-Mg-Si (6061Al -T4) plates of 6 mm thickness were subjected to bobbin tool friction stir welding (BT-FSW) and conventional friction stir welding (C-FSW) for comparison. How the welding process affects the microstructure and mechanical properties was investigated at various rotation rates and welding speeds. The results showed that butt FSW joints with high quality could be produced at the selected parameters. The joint strength rose with enhanced welding speed and was nearly independent of the rotation rate in both the welding processes. The strength of the joints produced with BT-FSW reached the same level as that of the C-FSW. The maximum joint strength of 229 MPa was 93% of the base material (BM), which is superior to the reported results of 60–80% for the T4 condition. The fracture position of most of the joints was in the heat-affected zone (HAZ), which is the lowest hardness zone.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Microstructure and mechanical properties of friction stir welded Haynes 282

Advanced ultrasupercritical (A-USC) steam plants are designed to operate at high temperatures and pressures due to the necessity for higher operational efficiency. The extreme operating conditions of A-USC requires the deployment of precipitation strengthened Ni-base alloys that exhibit elevated temperature strength and good fabricability. Fusion welding of precipitation strengthened nickel alloys lead to solidification cracking in fusion zone and/or liquation cracking in heat affected zone. Therefore, an alternative non-melting welding technique is a necessity to efficiently join nickel alloys. In the current study, friction stir welding, a solid state joining technique was implemented on a precipitation strengthened nickel-based superalloy, Haynes 282. Detailed microstructural and mechanical properties characterization was carried out. The processed region exhibited wrought, fine-grained microstructure, absence of weld defects such as voids and cracks and absence of elemental segregation. Both hardness and cross-weld tensile tests demonstrated that the weld region was stronger than the base material. And the cross-weld tensile samples failed in the base material. Based on joint efficiency analysis, friction stir welded Haynes 282 outperformed fusion welds.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Elucidating microstructural evolution and hardness variation across friction self-piercing riveted Al-7055 using synchrotron X-ray scattering and advanced microscopy techniques

Friction self-piercing riveting (FSPR) is a unique hybrid joining technique that combines the advantages of mechanical interlocking, frictional heat, and solid-state joining (if metallurgically compatible) to produce crack free joints in high strength and/or low-ductility alloys at room temperature. Here, in the current study, Al-7055 sheets were joined using FSPR for lightweight automotive applications and significant microhardness variations were observed across the joint cross-section. A detailed microstructural characterization at multiple length scales was carried out using advanced electron microscopy and X-ray scattering techniques to provide a fundamental understanding of the process-structure-property relationships. The relative contributions of microstructural characteristics at various length scales (i.e., grain size, dislocation density, solute concentration, precipitate nature) to strengthening were estimated using existent formulations (i.e., Hall-Petch, Taylor, precipitate bypass/shear equations) and correlated to the observed microhardness values across different regions. Small-angle X-ray scattering and scanning transmission electron microscopy revealed significant changes in the size and volume fraction of precipitate species, i.e., GP-I Zones, η′, and Mg/Zn solute co-clusters, depending on the process region. It was observed that the dissolution of the small η′/GP-I zones (T ∼ 150–200 °C) in the heat-affected zone were the key reason for the hardness drop. Further, it was shown that solid-solution, dislocation, grain size and solute co-cluster strengthening played a key role in the thermo-mechanically affected zone and grain-refined zone (GRZ). Finally, these observations were leveraged along with the Zener-Holloman relationship and grain size in the GRZ to estimate the peak joining temperature of the GRZ (∼ 350 °C) near the steel rivet.

aluminum 7xxx alloy↗
DOE OSTI2022

Towards underwater additive manufacturing via additive friction stir deposition

Given the challenges in feed material supply and quality control, metal additive manufacturing has rarely been implemented in austere environments, especially underwater. This paper explores the underwater operation potential of an emerging solid-state additive technology: additive friction stir deposition, wherein material feeding and bonding are enabled by mechanical forces with minimal influences from water. It is demonstrated that additive friction stir deposition of 304 stainless steel can be successfully performed with the print head and substrate immersed in water. High temperature is reached in the deposition zone (>60% melting temperature); the material deposition behavior is similar to that in typical open-air operation. The as-deposited material is fully-dense, having fewer annealing twins and a substantially smaller grain size than the feed material (4.98 μm vs. 31.44 μm ). Such microstructural changes stem from dynamic recrystallization caused by the large strain and high temperature introduced during deposition. In addition to grain refinement, small equiaxed dispersoids (~2–3 μm or less) are formed and evenly distributed in the austenite steel matrix. Rich in Cr, Mn, and O, these particles likely result from the reaction between the elements in stainless steel and water at elevated temperatures.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

High-speed friction stir butt welding of 25.4 mm thick 7175-T79 aluminum alloy

This presents the first experimental demonstration of friction stir butt welding of 25.4 mm thick high-strength, precipitate-strengthened 7XXX aluminum alloy at a welding speed above 500 mm/min and penetration depth greater than 10 mm. Tool pin threads that terminate away from the shoulder region, helped mitigate nearby stress concentration during tool traversing, enabling a higher welding speed while avoiding pin fracture near shoulder. Two kinds of welds—one-sided with full penetration of the plate thickness and double-sided with partial penetration of the plate thickness—were conducted. Significant grain refinement (grain size 1.3 ± 0.8 µm) was evident at the junction of double-sided friction stir welding (FSW) compared to other regions of weld-nugget or base material. Cross-weld tensile testing with digital image correlation revealed high local strains at the junction of double-sided FSW before macro-yield. This strain concentration impeded the typical early necking on advancing/retreating sides of FSW joints, improving the yield strength of as-welded double-sided FSW by 20–24% over slow- to medium-speed one-sided FSW. In conclusion, the joint efficiency of as-welded, double-sided high-speed FSW was about 76% with respect to the base material’s ultimate tensile strength.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Characterization of Residual Stress as a Function of Friction Stir Welding Parameters in Oxide Dispersion Strengthened (ODS) Steel MA956

This article characterizes the residual stresses generated by friction stir welding of oxide dispersion strengthened steel MA956 over a series of welding conditions. A plate of MA956 steel was friction stir welded at three conditions: 500 rpm/25 millimeters per minute (mmpm), 400 rpm/50 mmpm and 400 rpm/100 mmpm. The residual stresses across these welds were measured using both x-ray and neutron diffraction techniques. Longitudinal residual stresses up to eighty percent of the yield strength were observed for the 400 rpm/100 mmpm condition. Increasing the traverse rate while holding the rotational speed fixed increased the residual stress levels in the stir zone and at the stir zone-thermomechanically affected zone interface. The stress profiles displayed the characteristic M shape, and the asymmetry between advancing and retreating stress peaks was limited, occurring mainly on the root side of the weld. The large magnitude of the stresses was maintained throughout the thickness of the plates.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influence of friction stir processing on the room temperature fatigue cracking mechanisms of A356 aluminum alloy

Here, failure by fatigue is a common problem associated with cast aluminum alloys due to defects like shrinkage porosities, non-metallic inclusions, etc. Friction stir processing (FSP) has recently emerged as an effective technique for local modification of microstructure. This study investigates the fatigue crack initiation and growth mechanisms in cast and FSPed A356 aluminum alloy. Two sets of parameters were used to friction stir the cast alloy resulting in the complete modification the cast microstructure to a wrought microstructure. Both the FSPed microstructures exhibited severe abnormal grain growth (AGG) after heat treatment leading to a multimodal grain size distribution – the grain sizes ranging from a few microns to a few millimeters. One of the FSP conditions displayed an excellent improvement in fatigue life by an order of magnitude, while the other condition displayed an unexpectedly large scatter in fatigue lives. Detailed study of the fractured fatigue specimens by electron back scattered diffraction (EBSD) revealed that both, fatigue crack initiation and propagation, were intimately tied to the grain size as well as the grain misorientations in the microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Interfacial microstructure and mechanical properties of rotary inertia friction welded dissimilar 422 martensitic stainless steel to 4140 low alloy steel joints

In this work, dissimilar rotary inertia friction welds between 422 martensitic stainless steel and 4140 martensitic low-alloy steel were made to fabricate prototype heavy-duty diesel engine pistons. The influence of the inertia friction welding process and post weld heat treatment (PWHT) temperature on the interfacial microstructure evolutions and corresponding effects on mechanical properties of the 422/4140 welds were evaluated in detail. Carbon diffused from the 4140 side to the 422 side during PWHT at 650 °C for 1.5 h, causing the formation of a hard carbide-rich layer on the 422 side, and a softer but discontinuous C-depleted layer the 4140 side. PWHT at 700 °C for 1.5 h greatly accelerated C diffusion across the interface relative to 650 °C, resulting in a thicker hard carbide-rich layer and a relatively thick and continuous layer of coarse C-depleted grains (ferrite) on the 4140 side. In addition, the PWHT temperature greatly influenced the tensile properties and fracture behavior of the welds, with the 650 °C PWHT-ed samples failing predominately in a ductile manner in the 4140 heat affected zone during tensile testing. Conversely, the 700 °C PWHT specimens exhibited a strength reduction compared with the 650 °C PWHT specimens because of additional coarsening of the interfacial ferrite layer and softening of the base materials during PWHT, with brittle fracture between the hard and soft layers the predominate failure mechanism. Based on the findings, a reduced PWHT temperature and/or time, minimizing the hardness differential of the base metals, and pre-heating the 422 steel prior to welding are the potential pathways to achieve a more optimal balance between desirable tempering and stress relief of the weld microstructure and undesirable C migration across the weld interface, and to reduce the strength mismatch across the weld.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Friction surfacing and cold spray deposition for surface crack repair in austenitic stainless steels

Two technologies, friction surfacing (FS) and cold spray deposition (CSD), have been investigated for field repair of cracks in 304L austenitic stainless steel. Both technologies are low-heat-input, solid-state technologies that do not introduce the detrimental effects of solidification, such as compositionally segregated microstructures and shrinkage stresses. Friction surfacing was performed using a 304L stainless steel rod over the substrate of the same material. Further, the process was performed at a high spindle speed of 20,000 RPM allowing for process forces below 500N to be used effectively. Spherical gas-atomized 304L stainless steel powder, in size range of 25–44 µm, was used as feedstock powder for the cold spray process for deposition on 304L substrates. Both technologies showed leak-tight crack repair capabilities on ~30–50 µm wide simulated through-crack specimens based on helium leak tests.

36 MATERIALS SCIENCE↗
DOE OSTI2023

In-situ measurement and control of the tool-workpiece interface temperature during friction stir processing of 304/304L stainless steel

Friction stir processing of 304/304L stainless steel is an area of interest for repair of spent nuclear fuel canisters. To enable repair without canister deflection or fracture, it is necessary to define the limitations for the depth of the processing zone which will be critically dependent on the thermal history of the material. Here, this work provides the first direct measurement of the interface temperature for friction stir processing of steel. The measured temperature is in the range of 850–1050 °C which is 20–30 % higher than previously reported values. Notably, the peak temperature occurs at the pin tip which is attributed to a higher sticking fraction and subsequently higher strain rate near the tool axis of rotation. Furthermore, a clear correlation between the temperature, grain size, and hardness is established within a single weld nugget and across different processing conditions. In the future, this data may lead to improved process modelling through direct validation and allow for property optimization through direct microstructure control.

304 stainless steel↗
DOE OSTI2020

Tribochemical Conversion of Methane to Graphene and Other Carbon Nanostructures: Implications for Friction and Wear

Tribochemistry involves chemical reactions occurring at sliding contact interfaces in the presence of gaseous and/or liquid media. It often leads to the formation of a solid reaction film (also termed boundary film) which controls friction and wear and hence the efficiency and reliability of moving mechanical systems (such as engines). Here we demonstrate tribochemical conversion of methane to graphene, nano-onion, and disordered carbons on the sliding surfaces of Ni-, Cu-, and CuNi-containing VN coatings at atmospheric pressure and room temperature, providing 2-3 orders of magnitude reduction in wear and similar to 50% reduction in friction compared to those of the uncoated steels. Transmission electron microscopy confirms that graphene forms preferably on metal rich nanoclusters of the composite coatings, while the carbon nano-onions are scattered throughout the carbon tribofilm. Ab initio molecular dynamics simulations elucidate underlying mechanisms involved in the tribochemical conversion of methane to carbon- based nanostructures in support of microscopic observations. These scientific findings may lead to new materials technologies that can use methane as a source for continuous and in situ lubrication. For example, there is an urgent need to curtail the uses of lubricating oils in natural gas compressors and engines as they contaminate the natural gas being compressed or burnt.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Machine Learning Reveals the State of Intermittent Frictional Dynamics in a Sheared Granular Fault

Seismogenic plate boundaries are posited to behave in a similar manner to a densely packed granular medium, where fault and block systems rapidly rearrange the distribution of forces within themselves, as particles do in slowly sheared granular systems. Machine learning is used to show that statistical features of velocity signals from individual particles in a simulated sheared granular fault contain information regarding the instantaneous global state of intermittent frictional stick-slip dynamics. We demonstrate that combining features built from the signals of more particles can improve the accuracy of the global model and discuss the physical basis behind the decrease in error. We show that the statistical features such as median and higher moments of the signals that represent the particle displacement in the direction of shearing are among the best predictive features. We demonstrate here novel insights into the applications of machine learning in studying frictional processes occurring in geophysical systems.

58 GEOSCIENCES↗
DOE OSTI2014

Friction imprint effect in mechanically cleaved BaTiO{sub 3} (001)

Adsorption, chemisorption, and reconstruction at the surfaces of ferroelectric materials can all contribute toward the pinning of ferroelectric polarization, which is called the electrical imprint effect. Here, we show that the opposite is also true: freshly cleaved, atomically flat surfaces of (001) oriented BaTiO{sub 3} exhibit a persistent change in surface chemistry that is driven by ferroelectric polarization. This surface modification is explored using lateral force microscopy (LFM), while the ferroelectric polarization is probed using piezoresponse force microscopy. We find that immediately after cleaving BaTiO{sub 3}, LFM reveals friction contrast between ferroelectric domains. We also find that this surface modification remains after the ferroelectric domain distribution is modified, resulting in an imprint of the original ferroelectric domain distribution on the sample surface. This friction imprint effect has implications for surface patterning as well as ferroelectric device operation and failure.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Features of the microstructure development under conditions, reproducing the process of friction stir welding. Molecular-dynamics study

Friction stir welding is a recently developed technology which is used in various branches of modern engineering. The basis of this technology is the friction of the rotating cylindrical or specially shaped tool between two metal plates brought together either to meet their ends of one above another with the overlap. When applying the FSW process in various economical sectors, the important task is to study the mechanisms and identify the physical laws and factors leading to formation of structural inhomogeneities and discontinuities in the weld seam. This paper analyzes the basic mechanisms behind the structural state generation in the material subjected to severe plastic deformation and heating. To investigate the atomic mechanisms of structural changes in FSW, the modeling at atomic scale has been carried out. Results of work can be a basis for new knowledge about the microstructure evolution in FSW.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Effects of Coulomb coupling on friction in strongly magnetized plasmas

The friction force on a test particle traveling through a plasma that is both strongly coupled and strongly magnetized is studied using molecular dynamics simulations. In addition to the usual stopping power component aligned antiparallel to the velocity, a transverse component that is perpendicular to both the velocity and Lorentz force is observed. This component, which was recently discovered in weakly coupled plasmas, is found to increase in both absolute and relative magnitude in the strongly coupled regime. Strong coupling is also observed to induce a third component of the friction force in the direction of the Lorentz force. These first-principles simulations reveal novel physics associated with collisions in strongly coupled, strongly magnetized, plasmas that are not predicted by existing kinetic theories. The effect is expected to influence macroscopic transport in a number of laboratory experiments and astrophysical plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Fabrication of thick multilayered steel structure using A516 Grade 70 by multipass friction stir welding

In the present work, a thick-sectioned multilayered steel structure was fabricated by multipass friction stir welding on A516 Grade 70 steel. Tensile strength of the multilayered samples was comparable to that of the base metal. Failure was located in the base metal when a defect-free sample was tested. Charpy impact toughness was higher in the stir zone and heat affected zone than in the base metal. Higher microhardness values were found in the stir zone and heat affected zone than the base metal due to grain refinement and modification of the microstructures. Consequently, improved mechanical properties compared to the base metal were found in the weld zones of friction stir welded A516 Grade 70 steel.

36 MATERIALS SCIENCE↗