Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “FRICTION”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 793 records · Page 44

Frictional Coefficients between Aluminum–Silicon Alloy and Cutting Inserts with MPCVD Diamond Coatings

The frictional coefficients at the front and rear surfaces of a VK6 hard-alloy cutter with experimental nano- and microcrystalline CVD diamond coatings applied in microwave plasma are determined by extrapolation to zero cut-layer thickness. It is found that, for diamond coatings with a single microcrystalline layer and those with both a microcrystalline layer and a nanocrystalline layer, the frictional coefficients are less than for an uncoated hard-alloy cutter and also for a cutter with a Sandvik diamond coating.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Friction Stir Welding in the Aerospace Industry

Friction stir welding (FSW) is studied as a method of permanent bonding in special aerospace structures made of aluminum, titanium, and magnesium alloys and high-temperature steels. Experimental and industrial equipment for high-speed friction stir welding is presented. A manufacturing technology has been developed for a very hard wear-resistant welding tool of complex shape that is applicable to aviation materials.

36 MATERIALS SCIENCE↗

Microstructural Assessment of a Multiple-Intermetallic-Strengthened Aluminum Alloy Produced from Gas-Atomized Powder by Hot Extrusion and Friction Extrusion

An aluminum (Al) matrix with various transition metal (TM) additions is an effective alloying approach for developing high-specific-strength materials for use at elevated temperatures. Conventional fabrication processes such as casting or fusion-related methods are not capable of producing Al–TM alloys in bulk form. Solid phase processing techniques, such as extrusion, have been shown to maintain the microstructure of Al–TM alloys. In this study, extrusions are fabricated from gas-atomized aluminum powders (≈100–400 µm) that contain 12.4 wt % TM additives and an Al-based matrix reinforced by various Al–Fe–Cr–Ti intermetallic compounds (IMCs). Two different extrusion techniques, conventional hot extrusion and friction extrusion, are compared using fabricating rods. During extrusion, the strengthening IMC phases were extensively refined as a result of severe plastic deformation. Furthermore, the quasicrystal approximant IMC phase (70.4 wt % Al, 20.4 wt % Fe, 8.7 wt % Cr, 0.6 wt % Ti) observed in the powder precursor is replaced by new IMC phases such as Al3.2Fe and Al45Cr7-type IMCs. The Al3Ti-type IMC phase is partially dissolved into the Al matrix during extrusion. The combination of linear and rotational shear in the friction extrusion process caused severe deformation in the powders, which allowed for a higher extrusion ratio, eliminated linear voids, and resulted in higher ductility while maintaining strength comparable to that resulting from hot extrusion. Results from equilibrium thermodynamic calculations show that the strengthening IMC phases are stable at elevated temperatures (up to ≈ 600 °C), thus enhancing the high-temperature strength of the extrudates.

36 MATERIALS SCIENCE↗

EARTH’S ROTATIONAL DECELERATION: DETERMINATION OF TIDAL FRICTION INDEPENDENT OF TIMESCALES

This paper determines Earth's rotational deceleration without relying on atomic or ephemeris timescales. Earth's rotation defines the civil time standard called Universal Time (UT). Our previous paper did not examine tidal friction in depth when analyzing the timescale divergence between UT and International Atomic Time (TAI). We examine all available paleontological fossils and deposits for the direct measurements of Earth's past rotation rates, because that record includes all contributing effects. We examine paleontological reports that date Earth's rotation rate using corals, bivalves, brachiopods, rhythmites, and stromatolites. Contributions that vary Earth's moment of inertia, such as continental plate drifts, coastline changes, ice age formations, and viscous glacial rebounds, are superimposed with the secular deceleration. The average deceleration of Earth's rotation rate from all available fossil data is found to be (5.969 ± 1.762) × 10{sup −7} rad yr{sup −2}. Our value is 99.8% of the total rotational deceleration determined by Christodoulidis et al., who used artificial satellite data, and our value is 96.6% of the expected tidal friction value obtained by Stephenson and Morrison. Taking the derivative of conserved angular momentum, the predicted lunar orbital deceleration caused by the average rotational deceleration corresponds closely to lunar models. When evaluating the significant time gaps between UT and TAI, Earth's rotational deceleration is a minor contributing factor. Also, the secular deceleration rate is necessary to correctly date ancient astronomical events. We strongly encourage that more ocean paleontological evidence be found to supplement the record to separate the many periodic variations embedded in these data.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

On the turbulent friction layer for rising pressure

Among the information presented are included displacement, momentum, and kinetic energy thicknesses, shearing stress distributions across boundary layer, and surface friction coefficients. The Gruschwitz method and its modifications are examined and tested. An energy theorem for the turbulent boundary layer is introduced and discussed but does not lead to a method for the prediction of the behavior of the turbulent boundary layer because relations for the shearing stress and the surface friction are lacking.

SKIN FRICTION - PLATES↗

Characterization of Friction Joints Subjected to High Levels of Random Vibration

This paper describes the test program in detail including test sample description, test procedures, and vibration test results of multiple test samples. The material pairs used in the experiment were Aluminum-Aluminum, Aluminum- Dicronite coated Aluminum, and Aluminum-Plasmadize coated Aluminum. Levels of vibration for each set of twelve samples of each material pairing were gradually increased until all samples experienced substantial displacement. Data was collected on 1) acceleration in all three axes, 2) relative static displacement between vibration runs utilizing photogrammetry techniques, and 3) surface galling and contaminant generation. This data was used to estimate the values of static friction during random vibratory motion when "stick-slip" occurs and compare these to static friction coefficients measured before and after vibration testing.

aluminum↗

A Method for Obtaining Surface Flow Vectors and Its Implementation in Interferometric Skin Friction Measurement

A new method was developed to extract surface flow vectors from an oilflow visualization image that has oil streaklines. The method is analogous to the PIV processing where the image is divided into interrogation windows. A representative flow direction is obtained for each interrogation window using image processing with a line-detection algorithm. Repeating the process for the entire image, one can find the surface vector field. The Hough transformation, Radon transformation and Machine Learning were used as line-detection algorithms. The obtained vector field is then postprocessed to filter spurious vectors and to apply smoothing. The method was tested on 2D and 3D models with different flow complexities. The method was able to predict surface flow vectors for all cases tested. The predicted surface flow vectors were used in obtaining the surface skin friction. The successful implementation of the surface flow vectors enables interferometric skin friction measurements on surfaces beneath 3D complex flows. In addition, the surface flow vectors can be superimposed on the oilflow visualization images to better explain the surface flow topology.

Surface flow vectors↗

A Method for Obtaining Surface Flow Vectors and Its Implementation in Interferometric Skin Friction Measurement

A new method was developed to extract surface flow vectors from an oilflow visualization image that has oil streaklines. The method is analogous to the PIV processing where the image is divided into interrogation windows. A representative flow direction is obtained for each interrogation window using image processing with a line-detection algorithm. Repeating the process for the entire image, one can find the surface vector field. The Hough transformation, Radon transformation and Machine Learning were used as line-detection algorithms. The obtained vector field is then postprocessed to filter spurious vectors and to apply smoothing. The method was tested on 2D and 3D models with different flow complexities. The method was able to predict surface flow vectors for all cases tested. The predicted surface flow vectors were used in obtaining the surface skin friction. The successful implementation of the surface flow vectors enables interferometric skin friction measurements on surfaces beneath 3D complex flows. In addition, the surface flow vectors can be superimposed on the oilflow visualization images to better explain the surface flow topology.

Surface flow vectors↗

Role of Friction in Materials Selection for Automotive Applications

This is an invited article for a special issue of the ASM International monthly magazine that concerns "Automotive Materials and Applications." The article itself overviews frictional considerations in material selection for automobiles. It discusses implications for energy efficiency (engine friction) and safety (brakes) among other topics.

brakes↗

MODELING OF HIGH SPEED FRICTION STIR SPOT WELDING USING A LAGRANGIAN FINITE ELEMENT APPROACH

Friction stir spot welding (FSSW) has been shown to be capable of joining steels of very high strength, while also being very flexible in terms of controlling the heat of welding and the resulting microstructure of the joint. This makes FSSW a potential alternative to resistance spot welding (RSW) if tool life is sufficiently high, and if machine spindle loads are sufficiently low so that the process can be implemented on an industrial robot. Robots for spot welding can typically sustain vertical loads of about 8kN, but FSSW at tool speeds of less than 3000 rpm cause loads that are too high, in the range of 11-14 kN. Therefore, in the current work tool speeds of 3000 rpm and higher were employed, in order to generate heat more quickly and to reduce welding loads to acceptable levels. The FSSW process was modeled using a finite element approach with the Forge® software package. An updated Lagrangian scheme with explicit time integration was employed to model the flow of the sheet material, subjected to boundary conditions of a rotating tool and a fixed backing plate [3]. The modeling approach can be described as two-dimensional, axisymmetric, but with an aspect of three dimensions in terms of thermal boundary conditions. Material flow was calculated from a velocity field which was two dimensional, but heat generated by friction was computed using a virtual rotational velocity component from the tool surface. An isotropic, viscoplastic Norton-Hoff law was used to model the evolution of material flow stress as a function of strain, strain rate, and temperature. The model predicted welding temperatures and the movement of the joint interface with reasonable accuracy for the welding of a dual phase 980 steel.

Advanced High strength steel↗

Process Robustness of Friction Stir Dovetailing of AA7099 to Steel with In Situ AA6061 Interlayer Linking

Rolled homogeneous armor (RHA) steel was joined to aluminum alloy AA7099-T7451 with an interlayer of AA6061-T651 by single-pass friction stir dovetailing (FSD). The evolution of the AA7099/AA6061 and AA6061/steel interfacial microstructures and mechanical properties of the joints were examined. The AA6061 interlayer prevented Zn migration from the AA7099 to the steel during FSD and inhibited formation of brittle, Zn-rich, Fe-Al intermetallic compounds within the joint. The flow of the dissimilar aluminum alloys at the interface was controlled with a partially threaded friction stir welding pin and a dovetail geometric configuration optimized in previous work. The process robustness was explored to establish parameter windows by elucidating parametric effects on the relationship between process conditions and the joint’s microstructure and mechanical properties. Ranges of process forge force (50–70 kN) and interface temperature (475°C–515°C) consistently yielded joints with adequate performance. The load-carrying capacity in lap shear tensile tests was 2025 ? 100 N/mm.

Friction Stir Dovetailing, FSW, AA7099, AA6061, Ro↗

FRICTION STIR LAP WELDING OF ALUMINUM - POLYMER USING SCRIBE TECHNOLOGY

Friction Stir Scribe (FSS) technology is a relatively new variant of Friction Stir Welding (FSW) which enables lap joining of dissimilar material with very different melting points and different high temperature flow behaviors. The cutter scribe attached at the tip of FSW tool pin effectively cuts the high melting point material such that a mechanically interlocking feature is created between the dissimilar materials. The geometric shape of this interlocking feature determines the shear strength attained by the lap joint. This work presents first use of scribe technology in joining polymers to aluminum alloy. Details of the several runs of scribe welding performed in lap joining of ~3.175mm thick polymers including HDPE, filled and unfilled Nylon 66 to 2mm thick AA5182 are presented. The effect of scribe geometry and length on weld interlocking features is presented along with lap shear strength evaluations.

Upadhyay, Piyush↗

Defect‐Free Sound Insulator Using Single Metal‐Based Friction Stir Process Array

Metals are excellent conductors for phonon transportation such as vibration, sound, and heat. Generally, metal sound insulators require multimaterial structure or defects and unimetal sound insulators are challenging. Therefore, a design of a defect-free sound insulator made by single alloys with multiple friction stir processes (FSPs) is proposed. Periodic friction stir processing can induce superlattice-like local mechanical properties’ modifications. By experimental acoustic characterization, it is observed that FSP can introduce clear acoustic–elastic property contrast on an aluminum plate by the presence of stir zone and heat-affected zones. In numerical simulations, the signature FSP-induced property profile is periodically and parallelly arranged on a long aluminum plate. The transmission gap frequencies are present on the frequency spectrum with the sound propagation direction perpendicular to the FSP paths. Disorder offsets on FSP periodicity are further introduced. Anderson localization is found on a resonance frequency, which provides −11 dB sound reduction by an exponential decay. Due to the finite design length, the slight disorder can also enhance sound insulation in the periodic transmission gap frequency. In conclusion, with analysis and comparison with different configurations, the best performance in the models can achieve −30 dB sound insulation in the 350 mm-long aluminum alloy plate with 14 parallel FSPs.

36 MATERIALS SCIENCE↗

Joining of Lightweight Dissimilar Materials by Friction Self-Piercing Riveting

In this work, we employed a unique solid-state joining process, friction self-piercing riveting (F-SPR), to join carbon fiber composites to the low-ductility magnesium alloy AZ31B. The localized frictional heat generated between the rotating rivet and the underside of the magnesium sheet softened and prevented crack generation in AZ31B. A consumable joining rivet was designed to join the selected material stacks by F-SPR. Lap shear tensile testing was used to assess the joint quality of specimens produced by F-SPR. The joint interface from the cross-sectioned F-SPR specimen was evaluated by optical microscopy.

Lim, Yong Chae↗

Joining of High Strength Low Ductility AA7055 by Friction Self-piercing Rivet

High strength aluminum (Al) alloy is one of higher specific strength materials for decarbonization in transportation industries. Because of low ductility at room temperature, conventional mechanical fastening such as self-piercing riveting produces cracks at the joint. In this work, we applied friction self-piercing riveting to join Al alloy (AA) 7055. No cracks were observed in the joints because of the improved local ductility of Al alloy by the generated frictional heat during joining step. Numerical modeling of joining process was applied to guide rivet geometry design and rivet material strength. Mechanical integrity of the AA7055 joints was assessed by lap shear tensile and cross-tension testing. Metallurgical characterizations revealed solid-state bonding formed not only between the rivet and surround Al materials, but also upper and lower Al sheets at the joint interface. Both solid-state bonding and mechanical interlocking between the flared rivet and bottom AA7055 sheet were the major joint mechanisms.

Lim, Yong Chae↗

Friction Self-piercing Riveting Process for 3T Configuration of AA7075-AA7075-AA6022

Friction self-piercing riveting (F-SPR), as a solid-state joining process that generates frictional heat during the process, was utilized to join a 3 T configuration of low-ductility AA7075-AA7075-AA6022 sheets. A multi-step F-SPR process was employed to precisely control the mechanical interlocking and solid-state joining, ensuring a strong joint formation. With control of the plunge depth when the transition from rivet penetration to rivet flaring, two joining conditions were developed to assess mechanical joint integrity: one bearing deep penetration with a smaller interlock, and the other yielding a shallow penetration with a larger interlock. Both strategies met the criteria for a sound rivet joint. Customized lap shear tensile configurations were designed to assess the joint strength at interface between first and second layers, as well as between second and third layers. Both conditions demonstrated great joint strength between the first and second layers, while deeper penetration approach showed stronger solid-state joint, leading to improved joint strength between the second and third layers.

Wang, Tianzhao [ORNL] (ORCID:0000000315337602)↗

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)↗