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NASA NTRS2004

Convective Instability in Ice I with Non-Newtonian Rheology: Application to the Galilean Satellites

At the temperatures and stresses associated with the onset of convection in an ice I shell of the Galilean satellites, ice behaves as a non-Newtonian fluid with a viscosity that depends on both temperature and strain rate. The convective stability of a non-Newtonian ice shell can be judged by comparing the Rayleigh number of the shell to a critical value. Previous studies suggest that the critical Rayleigh number for a non-Newtonian fluid depends on the initial conditions in the fluid layer, in addition to the thermal, rheological, and physical properties of the fluid. We seek to extend the existing definition of the critical Rayleigh number for a non-Newtonian, basally heated fluid by quantifying the conditions required to initiate convection in an ice I layer initially in conductive equilibrium. We find that the critical Rayleigh number for the onset of convection in ice I varies as a power (-0.6 to -0.5) of the amplitude of the initial temperature perturbation issued to the layer, when the amplitude of perturbation is less than the rheological temperature scale. For larger-amplitude perturbations, the critical Rayleigh number achieves a constant value. We characterize the critical Rayleigh number as a function of surface temperature of the satellite, melting temperature of ice, and rheological parameters so that our results may be extrapolated for use with other rheologies and for a generic large icy satellite. The values of critical Rayleigh number imply that triggering convection from a conductive equilibrium in a pure ice shell less than 100 km thick in Europa, Ganymede, or Callisto requires a large, localized temperature perturbation of a few kelvins to tens of kelvins to soften the ice and therefore may require tidal dissipation in the ice shell.

Barr, A. C.↗

NASA NTRS2004

Convection in Icy Satellites: Implications for Habitability and Planetary Protection

Solid-state convection and endogenic resurfacing in the outer ice shells of the icy Galilean satellites (especially Europa) may contribute to the habitability of their internal oceans and to the detectability of any biospheres by spacecraft. If convection occurs in an ice I layer, fluid motions are confined beneath a thick stagnant lid of cold, immobile ice that is too stiff to participate in convection. The thickness of the stagnant lid varies from 30 to 50% of the total thickness of the ice shell, depending on the grain size of ice. Upward convective motions deliver approximately 10(exp 9) to 10(exp 13) kg yr(sup -1) of ice to the base of the stagnant lid, where resurfacing events driven by compositional or tidal effects (such as the formation of domes or ridges on Europa, or formation of grooved terrain on Ganymede) may deliver materials from the stagnant lid onto the surface. Conversely, downward convective motions deliver the same mass of ice from the base of the stagnant lid to the bottom of the satellites ice shells. Materials from the satellites surfaces may be delivered to their oceans by downward convective motions if material from the surface can reach the base of the stagnant lid during resurfacing events. Triggering convection from an initially conductive ice shell requires modest amplitude (a few to tens of kelvins) temperature anomalies to soften the ice to permit convection, which may require tidal heating. Therefore, tidal heating, compositional buoyancy, and solid-state convection in combination may be required to permit mass transport between the surfaces and oceans of icy satellites. Callisto and probably Ganymede have thick stagnant lids with geologically inactive surfaces today, so forward contamination of their surfaces is not a significant issue. Active convection and breaching of the stagnant lid is a possibility on Europa today, so is of relevance to planetary protection policy.

Barr, A. C.↗

NASA NTRS2005

Hard X-ray Spectroscopic, Microwave and H-alpha Linear Polarization Studies with Hard X-Ray Observations from HESSI

The Principal Investigator (P.I.) has been pursuing a three year grant under NASA's Sun-Earth Connection Guest Investigator Program in support of the Ramaty High Energy Solar Spectroscopic Imager (RHESSI). An objective of these efforts is to combine X-ray and other data on solar flares, coronal mass ejections and interplanetary particle events in order to obtain a more comprehensive recognition of signatures, and understanding of interplanetary proton events. Thus, part of these efforts are to investigate if signatures seen in hard X-rays and microwaves can lead to better predictions of interplanetary proton events that can be dangerous to astronauts and spacecraft. The original proposal was written in May, 2000 and it discusses a three-pronged approach for data comparisons with three new types of instrumentation observing at X-ray, microwave and optical wavelengths. The major impetus behind this work and the proposal is that the P.I. discovered a strong correlation between a particular type of hard X-ray signature seen in spectral evolutions and interplanetary proton events (Kiplinger, 1995). The basic signature is that hard X-ray flux peaks either exhibit spectra that soften on their decays (Le. show fewer and fewer high energy X-rays with time) or they harden during decays (i.e. high energy X-rays decay significantly slower that lower energy X-rays). This signature is called progressive hardening. Studies were conducted over an eight-year period of data from the Hard X-Ray Burst Spectrometer (HXRBS) of the Solar maximum mission. Out of the 750 well observed flares studied, 41 flares had major associated proton events. Of these, 29 events were predicted on the basis of progressive hardening for a hit rate of 71%. The 152 largest flares had a hit rate of 82%.

Kiplinger, Alan L.↗

NASA NTRS2006

Swift Observations Of High-z Radio-loud Quasars Detected With Bat

We present follow-up Swift observations of 4 high-z radio-loud quasars detected with the BAT during the 15-month survey in 15-150 keV. The 0.5-8-keV spectra are best fitted either with a power law with no excess absorption over the Galactic value (0212+735, 0836+710, 2149--307 in higher state) or by a downward-curved broken power law model (0537--286, 2149--307 in lower state). The BAT spectra integrated over the whole 15 months of the survey are fitted with a single power law, with a range of spectral slopes, Gamma=l.3-2.3. Comparison with previous SAX observations shows that there is a trend for the 15-150-keV continuum to soften with fading intensity; on the contrary, little or no spectral variations are observed at medium-hard X-rays. This may suggest either/both dramatic variability above 10-keV, or/and two separate spectral components.

Sambruna, Rita M.↗

NASA NTRS1978

Foam For Filtering

Like nature's honeycomb, foam is a structure of many-sided cells, apparently solid but actually only three percent material and 97 percent air. Foam is made by a heat-producing chemical reaction which expands a plastic material in a manner somewhat akin to the heat-induced rising of a loaf of bread. The resulting structure of interconnected cells is flexible yet strong and extremely versatile in applicati6n. Foam can, for example, be a sound absorber in one form, while in another it allows sound to pass through it. It can be a very soft powder puff material and at the same time a highly abrasive scrubber. A sampling of foam uses includes stereo speaker grilles, applying postage meter ink, filtering lawnmower carburetor air; deadening noise in trucks and tractors, applying cosmetics, releasing fabric softener and antistatic agents in home clothes dryers, painting, filtering factory heating and ventilating systems, shining shoes, polishing cars, sponge-mopping floors, acting as pre-operative surgical scrubbers-the list is virtually limitless. The process by which foam is made produces "windows," thin plastic membranes connecting the cell walls. Windowed foam is used in many applications but for certain others-filtering, for example-it is desirable to have a completely open network. Scott Paper Company's Foam Division, Chester, Pennsylvania, improved a patented method of "removing the windows," to create an open structure that affords special utility in filtering applications. NASA technology contributed to Scott's improvement.

Source record↗

NASA NTRS2007

Materials-of-Construction Radiation Sensitivity for a Fission Surface Power Convertor

A fission reactor combined with a free-piston Stirling convertor is one of many credible approaches for producing electrical power in space applications. This study assumes dual-opposed free-piston Stirling engines/linear alternators that will operate nominally at 825 K hot-end and 425 K cold-end temperatures. The baseline design options, temperature profiles, and materials of construction discussed here are based on historical designs as well as modern convertors operating at lower power levels. This notional design indicates convertors primarily made of metallic components that experience minimal change in mechanical properties for fast neutron fluences less than 10(sup 20) neutrons per square centimeter. However, these radiation effects can impact the magnetic and electrical properties of metals at much lower fluences than are crucial for mechanical property integrity. Moreover, a variety of polymeric materials are also used in common free-piston Stirling designs for bonding, seals, lubrication, insulation and others. Polymers can be affected adversely by radiation doses as low as 10(sup 5) - 10(sup 10) rad. Additionally, the absorbing dose rate, radiation hardness, and the resulting effect (either hardening or softening) varies depending on the nature of the particular polymer. The classes of polymers currently used in convertor fabrication are discussed along possible substitution options. Thus, the materials of construction of prototypic Stirling convertor engines have been considered and the component materials susceptible to damage at the lowest neutron fluences have been identified.

Bowman, Cheryl L.↗

NASA NTRS2007

A Rapid Survey of the Compatibility of Selected Seal Materials with Conventional and Semi-Synthetic JP-8

Since the synthesis of a liquid hydrocarbon fuel from coal by Franz Fischer and Hans Tropsch in 1923, there has been cyclic interest in developing this fuel for military and commercial applications. In recent years the U.S. Department of Defense has taken interest in producing a unified battlespace fuel using the Fischer Tropsch (FT) process for a variety of reasons including cost, quality, and logistics. In the past year there has been a particular emphasis on moving quickly to demonstrate that an FT fuel can be used in the form of a blend with conventional petroleum-derived jet fuel. The initial objective is to employ this semi-synthetic fuel with blend ratios as high as 50 percent FT with longer range goals to use even high blend ratios and ultimately a fully synthetic jet fuel. A significant concern associated with the use of a semi-synthetic jet fuel with high FT blend ratios is the effect these low aromatic fuels will have on fuel-wetted polymeric materials, most notably seals and sealants. These materials typically swell and soften to some degree when exposed to jet fuel and the aromatic content of these fuels contribute to this effect. Semi-synthetic jet fuels with very low aromatic contents may cause seals and sealants to shrink and harden leading to acute or chronic failure. Unfortunately, most of the material qualification tests are more concerned with excessive swelling than shrinkage and there is little guidance offered as to an acceptable level of shrinkage or other changes in physical properties related to low aromatic content. Given the pressing need for guidance data, a program was developed to rapidly survey the volume swell of selected fuel-wetted materials in a range of conventional and semi-synthetic jet fuels and through a statistical analysis to make a determination as to whether there was a basis to be concerned about using fuels with FT blend ratios as high as 50 percent. Concurrent with this analysis data was obtained as to the composition of the fuel absorbed in fuel-wetted materials through the use of GC-MS analysis of swollen samples as well as other supporting data. In this presentation the authors will present a summary of the results of the volume swell and fuel absorbed by selected O-rings and sealants as well as a description of the measurement protocols developed for this program.

Graham, John L.↗

NASA NTRS1995

Optical fiber cable chemical stripping fixture

An elongated fixture handle member is connected to a fixture body member with both members having interconnecting longitudinal central axial bores for the passage of an optical cable therethrough. The axial bore of the fixture body member, however, terminates in a shoulder stop for the outer end of a jacket of the optical cable covering both an optical fiber and a coating therefor, with an axial bore of reduced diameter continuing from the shoulder stop forward for a predetermined desired length to the outer end of the fixture body member. A subsequent insertion of the fixture body member including the above optical fiber elements into a chemical stripping solution results in a softening of the exposed external coating thereat which permits easy removal thereof from the optical fiber while leaving a desired length coated fiber intact within the fixture body member.

Kolasinski, John R.↗

NASA NTRS2003

Inertial sensor and method of use

The inertial sensor of the present invention utilizes a proof mass suspended from spring structures forming a nearly degenerate resonant structure into which a perturbation is introduced, causing a split in frequency of the two modes so that the mode shape become uniquely defined, and to the first order, remains orthogonal. The resonator is provided with a mass or inertia tensor with off-diagonal elements. These off-diagonal elements are large enough to change the mode shape of the two nearly degenerate modes from the original coordinate frame. The spring tensor is then provided with a compensating off-diagonal element, such that the mode shape is again defined in the original coordinate frame. The compensating off-diagonal element in the spring tensor is provided by a biasing voltage that softens certain elements in the spring tensor. Acceleration disturbs the compensation and the mode shape again changes from the original coordinate frame. By measuring the change in the mode shape, the acceleration is measured.

Gutierrez, Roman C.↗

NASA NTRS2008

Deconvoluting the Friction Stir Weld Process for Optimizing Welds

In the friction stir welding process, the rotating surfaces of the pin and shoulder contact the weld metal and force a rotational flow within the weld metal. Heat, generated by the metal deformation as well as frictional slippage with the contact surface, softens the metal and makes it easier to deform. As in any thermo-mechanical processing of metal, the flow conditions are critical to the quality of the weld. For example, extrusion of metal from under the shoulder of an excessively hot weld may relax local pressure and result in wormhole defects. The trace of the weld joint in the wake of the weld may vary geometrically depending upon the flow streamlines around the tool with some geometry more vulnerable to loss of strength from joint contamination than others. The material flow path around the tool cannot be seen in real time during the weld. By using analytical "tools" based upon the principles of mathematics and physics, a weld model can be created to compute features that can be observed. By comparing the computed observations with actual data, the weld model can be validated or adjusted to get better agreement. Inputs to the model to predict weld structures and properties include: hot working properties ofthe metal, pin tool geometry, travel rate, rotation and plunge force. Since metals record their prior hot working history, the hot working conditions imparted during FSW can be quantified by interpreting the final microstructure. Variations in texture and grain size result from variations in the strain accommodated at a given strain rate and temperature. Microstructural data from a variety of FSWs has been correlated with prior marker studies to contribute to our understanding of the FSW process. Once this stage is reached, the weld modeling process can save significant development costs by reducing costly trial-and-error approaches to obtaining quality welds.

Schneider, Judy↗

NASA NTRS2008

Microstructural Evolution in Friction Stir Welding of Ti-6Al-4V

Friction stir welding (FSW) is a thermo-mechanical process that utilizes a nonconsumable rotating pin tool to consolidate a weld joint. In the conventional FSW process, the pin tool is responsible for generating both the heat required to soften the material and the forces necessary to deform and combine the weld seam. As such, the geometry of the pin tool is important to the quality of the weld and the process parameters required to produce the weld. Because the geometry of the pin tool is limitless, a reduced set of pin tools was formed to systematically study their effect on the weldment with respect to mechanical properties and resultant microstructure. In this study 0deg, 15deg, 30deg, 45deg, and 60deg tapered, microwave sintered, tungsten carbide (WC) pin tools were used to FSW Ti-6Al-4V. Transverse sections of the weld were used to test for mechanical properties and to document the microstructure using optical microscopy. X-ray diffraction (XRD) was also used to characterize the microstructure in the welds. FSW results for the 45deg and 60deg pin tools are reported in this paper.

Rubisoff, H.↗

NASA NTRS2008

Embossed Teflon AF Laminate Membrane Microfluidic Diaphragm Valves

A microfluidic system has been designed to survive spaceflight and to function autonomously on the Martian surface. It manipulates microscopic quantities of liquid water and performs chemical analyses on these samples to assay for the presence of molecules associated with past or present living processes. This technology lies at the core of the Urey Instrument, which is scheduled for inclusion on the Pasteur Payload of the ESA ExoMars rover mission in 2013. Fabrication processes have been developed to make the microfabricated Teflon-AF microfluidic diaphragm pumps capable of surviving extreme temperature excursions before and after exposure to liquid water. Two glass wafers are etched with features and a continuous Teflon membrane is sandwiched between them (see figure). Single valves are constructed using this geometry. The microfabricated devices are then post processed by heating the assembled device while applying pneumatic pressure to force the Teflon diaphragm against the valve seat while it is softened. After cooling the device, the embossed membrane retains this new shape. This solves previous problems with bubble introduction into the fluid flow where deformations of the membrane at the valve seat occurred during device bonding at elevated temperatures (100-150 C). The use of laminated membranes containing commercial Teflon AF 2400 sheet sandwiched between spun Teflon AF 1600 layers performed best, and were less gas permeable than Teflon AF 1600 membranes on their own. Spinning Teflon AF 1600 solution (6 percent in FLOURINERT(Registered TradeMark) FC40 solvent, 3M Company) at 500 rpm for 1.5 seconds, followed by 1,000 rpm for 3 seconds onto Borofloat glass wafers, results in a 10-micron-thick film of extremely smooth Teflon AF. This spinning process is repeated several times on flat, blank, glass wafers in order to gradually build a thick, smooth membrane. After running this process at least five times, the wafer and Teflon coating are heated under vacuum at 220 C for one hour in order to drive off any residual solvent present in the composite film. After this, a second blank, glass wafer is brought down from above and the stack is held under vacuum at 3 atm mechanical pressure for ten 10 hours.

Willis, Peter↗

NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗

NASA NTRS2009

Bonded Invar Clip Removal Using Foil Heaters

A new process uses local heating and temperature monitoring to soften the adhesive under Invar clips enough that they can be removed without damaging the composite underneath or other nearby bonds. Two 1x1 in. (approx.2.5x2.5 cm), 10-W/sq in. (approx.1.6-W/sq cm), 80-ohm resistive foil Kapton foil heaters, with pressure-sensitive acrylic adhesive backing, are wired in parallel to a 50-V, 1-A limited power supply. At 1 A, 40 W are applied to the heater pair. The temperature is monitored in the clip radius and inside the tube, using a dual thermocouple readout. Several layers of aluminum foil are used to speed the heat up, allowing clips to be removed in less than five minutes. The very local heating via the foil heaters allows good access for clip removal and protects all underlying and adjacent materials.

Pontius, James T.↗

NASA NTRS2010

Nitrous Oxide/Paraffin Hybrid Rocket Engines

Nitrous oxide/paraffin (N2OP) hybrid rocket engines have been invented as alternatives to other rocket engines especially those that burn granular, rubbery solid fuels consisting largely of hydroxyl- terminated polybutadiene (HTPB). Originally intended for use in launching spacecraft, these engines would also be suitable for terrestrial use in rocket-assisted takeoff of small airplanes. The main novel features of these engines are (1) the use of reinforced paraffin as the fuel and (2) the use of nitrous oxide as the oxidizer. Hybrid (solid-fuel/fluid-oxidizer) rocket engines offer advantages of safety and simplicity over fluid-bipropellant (fluid-fuel/fluid-oxidizer) rocket en - gines, but the thrusts of HTPB-based hybrid rocket engines are limited by the low regression rates of the fuel grains. Paraffin used as a solid fuel has a regression rate about 4 times that of HTPB, but pure paraffin fuel grains soften when heated; hence, paraffin fuel grains can, potentially, slump during firing. In a hybrid engine of the present type, the paraffin is molded into a 3-volume-percent graphite sponge or similar carbon matrix, which supports the paraffin against slumping during firing. In addition, because the carbon matrix material burns along with the paraffin, engine performance is not appreciably degraded by use of the matrix.

Zubrin, Robert↗

NASA NTRS2010

Resistance Curves in the Tensile and Compressive Longitudinal Failure of Composites

This paper presents a new methodology to measure the crack resistance curves associated with fiber-dominated failure modes in polymer-matrix composites. These crack resistance curves not only characterize the fracture toughness of the material, but are also the basis for the identification of the parameters of the softening laws used in the analytical and numerical simulation of fracture in composite materials. The method proposed is based on the identification of the crack tip location by the use of Digital Image Correlation and the calculation of the J-integral directly from the test data using a simple expression derived for cross-ply composite laminates. It is shown that the results obtained using the proposed methodology yield crack resistance curves similar to those obtained using FEM-based methods in compact tension carbon-epoxy specimens. However, it is also shown that the Digital Image Correlation based technique can be used to extract crack resistance curves in compact compression tests for which FEM-based techniques are inadequate.

Camanho, Pedro P.↗

NASA NTRS2006

Ion-Exclusion Chromatography for Analyzing Organics in Water

A liquid-chromatography technique has been developed for use in the quantitative analysis of urea (and of other nonvolatile organic compounds typically found with urea) dissolved in water. The technique involves the use of a column that contains an ion-exclusion resin; heretofore, this column has been sold for use in analyzing monosaccharides and food softeners, but not for analyzing water supplies. The prior technique commonly used to analyze water for urea content has been one of high-performance liquid chromatography (HPLC), with reliance on hydrophobic interactions between analytes in a water sample and long-chain alkyl groups bonded to an HPLC column. The prior technique has proven inadequate because of a strong tendency toward co-elution of urea with other compounds. Co-elution often causes the urea and other compounds to be crowded into a narrow region of the chromatogram (see left part of figure), thereby giving rise to low chromatographic resolution and misidentification of compounds. It is possible to quantitate urea or another analyte via ultraviolet- and visible-light absorbance measurements, but in order to perform such measurements, it is necessary to dilute the sample, causing a significant loss of sensitivity. The ion-exclusion resin used in the improved technique is sulfonated polystyrene in the calcium form. Whereas the alkyl-chain column used in the prior technique separates compounds on the basis of polarity only, the ion-exclusion-resin column used in the improved technique separates compounds on the basis of both molecular size and electric charge. As a result, the degree of separation is increased: instead of being crowded together into a single chromatographic peak only about 1 to 2 minutes wide as in the prior technique, the chromatographic peaks of different compounds are now separated from each other and spread out over a range about 33 minutes wide (see right part of figure), and the urea peak can readily be distinguished from the other peaks. Although the analysis takes more time in the improved technique, this disadvantage is offset by two important advantages: Sensitivity is increased. The minimum concentration of urea that can be measured is reduced (to between 1/5 and 1/3 of that of the prior technique) because it is not necessary to dilute the sample. The separation of peaks facilitates the identification and quantitation of the various compounds. The resolution of the compounds other than urea makes it possible to identify those compounds by use of mass spectrometry.

Sauer, Richard↗

NASA NTRS2006

Heat Treatment of Friction-Stir-Welded 7050 Aluminum Plates

A method of heat treatment has been developed to reverse some of the deleterious effects of friction stir welding of plates of aluminum alloy 7050. This alloy is considered unweldable by arc and high-energy-density beam fusion welding processes. The alloy can be friction stir welded, but as-welded workpieces exhibit low ductility, low tensile and yield strengths, and low resistance to stress corrosion cracking. Heat treatment according to the present method increases tensile and yield strengths, and minimizes or eliminates stress corrosion cracking. It also increases ductility. This method of heat treatment is a superior alternative to a specification-required heat treatment that caused the formation of large columnar grains, which are undesired. Workpieces subjected to the prior heat treatment exhibited elongations <2 percent, and standard three-point bend specimens shattered. The development of the present heat treatment method was guided partly by the principles that (1) by minimizing grain sizes and relieving deformation stresses, one can minimize or eliminate stress corrosion cracking and (2) the key to maximizing strength and eliminating residual stresses is to perform post-weld solution heating for as long a time as possible while incurring little or no development of large columnar grains in friction stir weld nuggets. It is necessary to perform some of the solution heat treatment (to soften the alloy and improve machine welding parameters) before welding. The following is an example of thickness- dependent pre- and post-weld heat treatments according to the present method: For plates 0.270 in. (approx.6.86 mm) thick milled from plates 4.5 in. (114.3 mm) thick, perform pre-weld solution heating at 890 F (477 C) for 1 hour, then cool in air. After friction stir welding, perform solution heating for 10 minutes, quench, hold at room temperature for 96 hours, then age at 250 F (121 C) for 5 hours followed by 325 F (163 C) for 27 hours.

Petter, George E.↗