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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.

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At least 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Counterrotating-Shoulder Mechanism for Friction Stir Welding

A counterrotating-shoulder mechanism has been proposed as an alternative to the mechanism and fixtures used in conventional friction stir welding. The mechanism would internally react most or all of the forces and torques exerted on the workpiece, making it unnecessary to react the forces and torques through massive external fixtures. In conventional friction stir welding, a rotating pin tool is inserted into, and moved along, a weld seam. As the pin tool moves, it stirs together material from the opposite sides of the seam to form the weld. A large axial plunge force must be exerted upon the workpiece through and by the pin tool and a shoulder attached above the pin tool in order to maintain the pressure necessary for the process. The workpiece is secured on top of an anvil, which supports the workpiece against the axial plunge force and against the torque exerted by the pin tool and shoulder. The anvil and associated fixtures must be made heavy (and, therefore, are expensive) to keep the workpiece stationary. In addition, workpiece geometries must be limited to those that can be accommodated by the fixtures. The predecessor of the proposed counterrotating-shoulder mechanism is a second-generation, self-reacting tool, resembling a bobbin, that makes it possible to dispense with the heavy anvil. This tool consists essentially of a rotating pin tool with opposing shoulders. Although the opposing shoulders maintain the necessary pressure without need to externally apply or react a large plunge force, the torque exerted on the workpiece remains unreacted in the absence of a substantial external fixture. Depending on the RPM and the thickness of the workpiece, the torque can be large. The proposed mechanism (see figure) would include a spindle attached to a pin tool with a lower shoulder. The spindle would be coupled via splines to the upper one of three bevel gears in a differential drive. The middle bevel gear would be the power-input gear and would be coupled to the upper and lower bevel gears. The lower bevel gear would be attached to the upper shoulder and would slide and rotate freely over the spindle. The spindle would be fastened by its threaded upper end to an external submechanism that would exert axial tension on the spindle to load the workpiece in compression between the shoulders. By reducing or eliminating (relative to the use of a self reacting tool) the torque that must be reacted externally, the use of the proposed tool would reduce the tendency toward distortion or slippage of the workpiece. To begin a weld, the spindle would be inserted through a hole in the workpiece or run-on tab at the beginning of the seam and fastened to the loading submechanism. Rotation and axial loading would be increased gradually from zero and, after a time to be determined by trial and error, translation along the weld seam would be increased gradually from zero to a steady weld speed. The weld would be ended by running the mechanism off the workpiece or, if the lower shoulder were detachable, by detaching the lower shoulder from the spindle and pulling the pin tool out.

Nunes, Arthur C., Jr.↗
NASA NTRS2006

Tool for Two Types of Friction Stir Welding

A tool that would be useable in both conventional and self-reacting friction stir welding (FSW) has been proposed. The tool would embody both a prior tooling concept for self-reacting FSW and an auto-adjustable pin-tool (APT) capability developed previously as an augmentation for conventional FSW. Some definitions of terms are prerequisite to a meaningful description of the proposed tool. In conventional FSW, depicted in Figure 1, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a rotating pin that protrudes from the shoulder into the depth of the workpiece. The main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional FSW is augmented with an APT capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or force-control system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding (SR-FSW), there are two rotating shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft, back into the FSW machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. A tool for SRFSW embodying this concept was reported in "Mechanism for Self-Reacted Friction Stir Welding" (MFS-31914), NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 53. In its outward appearance, the proposed tool (see Figure 2) would fit the above description of an SR-FSW tool. In this case, the FSW machine would have an APT capability and the pin would be modified to accept a bottom shoulder. The APT capability could be used to vary the distance between the front and back shoulders in real time to accommodate process and workpiece-thickness variations. The tool could readily be converted to a conventional FSW tool, with or without APT capability, by simply replacing the modified pin with a conventional FSW pin.

Carter, Robert↗
NASA NTRS2011

Stemless ball valve

A stemless ball valve comprising two flanges and a ball with a channel, two axis pins and two travel pins. One end of each axis and travel pin is fixedly attached to the ball, and the other end of each axis pin is lodged into a notch in the first or second flange such that the axis pin is allowed to rotate in the notch. The guide sleeve comprises two channels, and one end of each travel pin is situated within one of the two channels in the guide sleeve. An outer magnetic cartridge causes the inner magnetic cartridge and guide sleeve to rotate, and when the guide sleeve rotates, the travel pins move up and down within the channels in the guide sleeve. The movement of the travel pins within the channels in the guide sleeve causes the ball to rotate, thereby opening and closing the ball valve.

Burgess, Kevin↗
NASA NTRS2013

High-Powered, Ultrasonically Assisted Thermal Stir Welding

This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a distance equal to the thickness of the material being welded. The TSW process can be significantly improved by reducing the draw forces. This can be achieved by reducing the friction forces between the weld workpieces and the containment plates. High-power ultrasonic (HPU) vibrations of the containment plates achieve friction reduction in the TSW process. Furthermore, integration of the HPU energy into the TSW stir rod can increase tool life of the stir rod, and can reduce shear forces to which the stir rod is subjected during the welding process. TSW has been used to successfully join 0.500-in (≈13-mm) thick commercially pure (CP) titanium, titanium 6AL- 4V, and titanium 6AL-4V ELI in weld joint lengths up to 9 ft (≈2.75-m) long. In addition, the TSW process was used to fabricate a sub-scale hexagonally shaped gun turret component for the U.S. Navy. The turret is comprised of six 0.5000-in (≈13-mm) thick angled welds. Each angled weld joint was prepared by machining the mating surfaces to 120deg. The angled weld joint was then fixtured using an upper and lower containment plate of the same geometry of the angled weld joint. The weld joint was then stirred by the stir rod as it and the upper and lower containment plates traverse through the angled joint prep.

Ding, Robert↗
DOE OSTI2022

Selectively adjustable interface assembly

A system includes a first component, a second component, a locking pin, and an interface assembly that is configured to selectively adjust a stiffness of a coupling interface between the first component and the second component. The interface assembly includes at least one support coupler secured to the first component. The support coupler(s) includes a main body, a first arm extending from a first side of the main body, a second arm extending from a second side of the main body, and a flange extending from the main body. The flange includes a locking pin hole that is configured to selectively receive the locking pin. The locking pin is selectively moveable between a retracted position in which the locking pin is out of the locking pin hole, and a deployed position in which the locking pin extends into the locking pin hole and a portion of the first component and locks the interface assembly to the first component.

42 ENGINEERING↗
DOE OSTI2014

Redwing: A MOOSE application for coupling MPACT and BISON

Fuel performance and whole core neutron transport programs are often used to analyze fuel behavior as it is depleted in a reactor. For fuel performance programs, internal models provide the local intra-pin power density, fast neutron flux, burnup, and fission rate density, which are needed for a fuel performance analysis. The fuel performance internal models have a number of limitations. These include effects on the intra-pin power distribution by nearby assembly elements, such as water channels and control rods, and the further limitation of applicability to a specified fuel type such as low enriched UO2. In addition, whole core neutron transport codes need an accurate intra-pin temperature distribution in order to calculate neutron cross sections. Fuel performance simulations are able to model the intra-pin fuel displacement as the fuel expands and densifies. These displacements must be accurately modeled in order to capture the eventual mechanical contact of the fuel and the clad; the correct radial gap width is needed for an accurate calculation of the temperature distribution of the fuel rod. Redwing is a MOOSE-based application that enables coupling between MPACT and BISON for transport and fuel performance coupling. MPACT is a 3D neutron transport and reactor core simulator based on the method of characteristics (MOC). The development of MPACT began at the University of Michigan (UM) and now is under the joint development of ORNL and UM as part of the DOE CASL Simulation Hub. MPACT is able to model the effects of local assembly elements and is able calculate intra-pin quantities such as the local power density on a volumetric mesh for any fuel type. BISON is a fuel performance application of Multi-physics Object Oriented Simulation Environment (MOOSE), which is under development at Idaho National Laboratory. BISON is able to solve the nonlinearly coupled mechanical deformation and heat transfer finite element equations that model a fuel element as it is depleted in a nuclear reactor. Redwing couples BISON and MPACT in a single application. Redwing maps and transfers the individual intra-pin quantities such as fission rate density, power density, and fast neutron flux from the MPACT volumetric mesh to the individual BISON finite element meshes. For a two-way coupling Redwing maps and transfers the individual pin temperature field and axially dependent coolant densities from the BISON mesh to the MPACT volumetric mesh. Details of the mapping are given. Redwing advances the simulation with the MPACT solution for each depletion time step and then advances the multiple BISON simulations for fuel performance calculations. Sub-cycle advancement can be applied to the individual BISON simulations and allows multiple time steps to be applied to the fuel performance simulations. Currently, only loose coupling where data from a previous time step is applied to the current time step is performed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Comparative post-irradiation examination of high burnup U-19Pu-10Zr: Assessing steady-state irradiation behavior against historical and modeled fuel performance

Here, the development of next-generation sodium-cooled fast reactors necessitates comprehensive research on metallic fuels to maximize economic performance while ensuring safe operation. In this study, we investigated the steady-state irradiation behavior of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, in preparation for planned safety testing. Post-irradiation examination (PIE) was performed to quantify fuel column elongation, regions of low-density at the top of the fuel column, pin deformation, fission product distribution, fractional fission gas release, microstructural evolution, and fuel constituent redistribution. Benchmarking against existing PIE data from U-19Pu-10Zr fuel pins irradiated in EBR-II revealed consistent patterns in fuel column elongation and cladding diametral strain. However, both pins exhibited longer low-density structures, and destructive examination of DP-36 revealed more complex constituent redistribution patterns compared to previously reported data for ternary fuel pins. The steady-state irradiation of both pins was also modeled using BISON. Comparisons of PIE results with modeled predictions showed overall agreement in fractional fission gas release but consistent overestimation of axial and radial swelling due to gaseous and solid swelling models. These findings underscore the critical importance of pre-test characterization on test and sibling pins to accurately capture steady-state fuel behavior ahead of transient testing, thus establishing a baseline for post-test comparison. Additionally, these analyses identified key data gaps that warrant further investigation to improve the understanding and prediction of fuel swelling, thereby enhancing the synergy between modeling and experimental efforts in supporting accident testing.

BISON↗
DOE OSTI2022

Commensuration effects on skyrmion Hall angle and drag for manipulation of skyrmions on two-dimensional periodic substrates

Here, we examine the dynamics of an individually driven skyrmion moving through a background lattice of skyrmions coupled to a 2D periodic substrate as we vary the ratio of the number of skyrmions to the number of pinning sites across commensurate and incommensurate conditions. As the skyrmion density increases, the skyrmion Hall angle is nonmonotonic, dropping to low or zero values in commensurate states and rising to an enhanced value in incommensurate states. Under commensuration, the driven skyrmion is channeled by a symmetry direction of the pinning array and exhibits an increased velocity. At fillings for which the skyrmion Hall angle is zero, the velocity has a narrow band noise signature, while for incommensurate fillings, the skyrmion motion is disordered and the velocity noise is broad band. Under commensurate conditions, multi-step depinning transitions appear and the skyrmion Hall angle is zero at low drives but becomes finite at higher drives, while at incommensurate fillings there is only a single depinning transition. As the gyrotropic component of the skyrmion dynamics, called the Magnus force, increases, peaks in the velocity that appear in commensurate regimes cross over to dips, and new types of directional locking effects can arise in which the skyrmion travels along other symmetry directions of the background lattice. At large Magnus forces, and particularly at commensurate fillings, the driven skyrmion can experience a velocity boost in which the skyrmion moves faster than the applied drive due to the alignment of the Magnus-induced velocity with the driving direction. In some cases, an increase of the Magnus force can produce regimes of enhanced pinning when the skyrmion is forced to move along a nonsymmetry direction of the periodic pinning array. This is in contrast to systems with random pinning, where increasing the Magnus force generally reduces the pinning effect. We demonstrate these dynamics for both square and triangular substrates and map out the different regimes as a function of filling fraction, pinning force, and the strength of the Magnus force in a series of dynamic phase diagrams.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Active matter shepherding and clustering in inhomogeneous environments

Here, we consider a mixture of active and passive run-and-tumble disks in an inhomogeneous environment where only half of the sample contains quenched disorder or pinning. The disks are initialized in a fully mixed state of uniform density. We identify several distinct dynamical phases as a function of motor force and pinning density. At high pinning densities and high motor forces, there is a two-step process initiated by a rapid accumulation of both active and passive disks in the pinned region, which produces a large density gradient in the system. This is followed by a slower species phase separation process where the inactive disks are shepherded by the active disks into the pin-free region, forming a nonclustered fluid and producing a more uniform density with species phase separation. For higher pinning densities and low motor forces, the dynamics becomes very slow and the system maintains a strong density gradient. For weaker pinning and large motor forces, a floating clustered state appears, and the time-averaged density of the system is uniform. We illustrate the appearance of these phases in a dynamic phase diagram.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Clogging and depinning of ballistic active matter systems in disordered media

We numerically examine ballistic active disks driven through a random obstacle array. Formation of a pinned or clogged state occurs at much lower obstacle densities for the active disks than for passive disks. As a function of obstacle density, we identify several distinct phases including a depinned fluctuating cluster state, a pinned single-cluster or jammed state, a pinned multicluster state, a pinned gel state, and a pinned disordered state. At lower active disk densities, a drifting uniform liquid forms in the absence of obstacles, but when even a small number of obstacles are introduced, the disks organize into a pinned phase-separated cluster state in which clusters nucleate around the obstacles, similar to a wetting phenomenon. Here in this paper, we examine how the depinning threshold changes as a function of disk or obstacle density and find a crossover from a collectively pinned cluster state to a disordered plastic depinning transition as a function of increasing obstacle density. We compare this to the behavior of nonballistic active particles and show that as we vary the activity from completely passive to completely ballistic, a clogged phase-separated state appears in both the active and passive limits, while for intermediate activity, a readily flowing liquid state appears and there is an optimal activity level that maximizes the flux through the sample.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Sliding dynamics for bubble phases on periodic modulated substrates

We analyze a bubble-forming system composed of particles with competing long-range repulsive and short-range attractive interactions driven over a quasi-one-dimensional periodic substrate. We find various pinned and sliding phases as a function of substrate strength and drive amplitude. When the substrate is weak, a pinned bubble phase appears that depins elastically into a sliding bubble lattice. For stronger substrates, we find anisotropic bubbles, disordered bubbles, and stripe phases. Plastic depinning occurs via the hopping of individual particles from one bubble to the next in a pinned bubble lattice, and as the drive increases, there is a transition to a state where all of the bubbles are moving but are continuously shedding and absorbing individual particles. This is followed at high drives by a moving bubble lattice in which the particles can no longer escape their individual bubbles. The transition between the plastic and elastic sliding phases can be detected via signatures in the velocity-force curves, differential conductivity, and noise. When the bubbles shrink due to an increase in the attractive interaction term, they fit better inside the pinning troughs and become more strongly pinned, leading to a reentrant pinning phase. For weaker attractive terms, the size of the bubbles becomes greater than the width of the pinning troughs and the depinning becomes elastic with a reduced depinning threshold. Published by the American Physical Society 2024

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Statics and dynamics of skyrmions interacting with disorder and nanostructures

Magnetic skyrmions are topologically stable nanoscale particlelike objects that were discovered in 2009. Since that time, intense research interest in the field has led to the identification of numerous compounds that support skyrmions over a range of conditions spanning from cryogenic to room temperatures. Skyrmions can be set into motion under various types of driving, and the combination of their size, stability, and dynamics makes them ideal candidates for numerous applications. At the same time, skyrmions represent a new class of system in which the energy scales of the skyrmion-skyrmion interactions, sample disorder, temperature, and drive can compete. A growing body of work indicates that the static and dynamic states of skyrmions can be influenced strongly by pinning or disorder in the sample; thus, an understanding of such effects is essential for the eventual use of skyrmions in applications. The current state of knowledge regarding individual skyrmions and skyrmion assemblies interacting with quenched disorder or pinning is reviewed. Additionally, the microscopic mechanisms for skyrmion pinning, including the repulsive and attractive interactions that can arise from impurities, grain boundaries, or nanostructures, are outlined. This is followed by descriptions of depinning phenomena, sliding states over disorder, the effect of pinning on the skyrmion Hall angle, the competition between thermal and pinning effects, the control of skyrmion motion using ordered potential landscapes such as one- or two-dimensional periodic asymmetric substrates, the creation of skyrmion diodes, and skyrmion ratchet effects. Highlighted are the distinctions arising from internal modes and the strong gyrotropic or Magnus forces that cause the dynamical states of skyrmions to differ from those of other systems with pinning, such as vortices in type-II superconductors, charge density waves, or colloidal particles. Throughout this review future directions and open questions related to the pinning and dynamics in skyrmion systems are also discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

MOOSE Framework Meshing Enhancements to Support Reactor Analysis

MOOSE-based physics codes require an input finite element mesh on which the physics solution is calculated, reported, and transferred to other physics codes. The use of difficult-touse, external licensed software is often required to generate high quality meshes for reactor geometries. High-fidelity geometry modeling also requires elaborate tracking of groups of elements for material property assignment and output reporting which can be considerably complex for the user to identify and maintain. Under the U.S. Department of Energy Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, several meshingrelated enhancements have been developed for the MOOSE framework to address user challenges in creating finite element meshes for advanced reactor geometries. MOOSE mesh generators have been developed to mesh hexagonal geometries (pins, ducted assemblies, and cores) commonly found in liquid-metal cooled fast reactor concepts. The mesh generator used for hexagonal pin cells is generic for regular polygons and therefore may also be used for Cartesian pin cells. Hexagonal pin cells can be stitched into ducted assemblies, and assemblies can be stitched together into a core. The user may specify region ids, region names, and other preferences on the mesh. This control is useful for later material mapping in the MOOSE-based physics codes input. A capability was also developed for meshing rotating control drums including determination of material volume fractions in each mesh element as a function of time. Control drum meshes may be stitched to other hexagonal assemblies to create a core configuration. Additional mesh generators were developed that wrap around the hexagonal meshing capabilities and utilize “extra element integer” ID values on each element. In regular Cartesian or hexagonal assemblies or cores, the bookkeeping of element groups for both material assignment and output reporting can now be automated through assignment of pin, assembly, core, axial and depletion id values stored as extra element integers. The extra element tags on the mesh greatly speed the reactor analyst’s efforts to map materials to meshes, track depletion zones, and parse output such as axial pin power distributions. At the highest level, pin, assembly, and core mesh generators (with this reactor terminology) have also been developed to easily generate regular Cartesian and hexagonal cores, including axial extrusion. These reactor geometry builders call upon the previously mentioned capabilities to produce analysis-ready 3D meshes including material assignments. Open source mesh triangulation capabilities were also investigated for integration into the MOOSE framework to address the need for meshing the core periphery region which extends from the irregular outer assembly border to a cylindrical boundary. Options are limited due to licensing constraints, and the recommendation is pursue building a native MOOSE Delaunay triangulator routine with full functionality. Finally, a series of verification problems were performed with NEAMS physics tools. All developed capabilities will be available in the new open-source “Reactor” module of the MOOSE framework, which is accessible to any MOOSE-based NEAMS physics tool.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Sliding Dynamics for Bubble Phases on Periodic Modulated Substrates

We analyze a bubble-forming system composed of particles with competing long-range repulsive and short range attractive interactions driven over a quasi-one-dimensional periodic substrate. We find various pinned and sliding phases as a function of substrate strength and drive amplitude. When the substrate is weak, a pinned bubble phase appears that depins elastically into a sliding bubble lattice. For stronger substrates, we find anisotropic bubbles, disordered bubbles, and stripe phases. Plastic depinning occurs via the hopping of individual particles from one bubble to the next in a pinned bubble lattice, and as the drive increases, there is a transition to a state where all of the bubbles are moving but are continuously shedding and absorbing individual particles. This is followed at high drives by a moving bubble lattice in which the particles can no longer escape their individual bubbles. The transition between the plastic and elastic sliding phases can be detected via signatures in the velocity-force curves, differential conductivity, and noise. When the bubbles shrink due to an increase in the attractive interaction term, they fit better inside the pinning troughs and become more strongly pinned, leading to a reentrant pinning phase. For weaker attractive terms, the size of the bubbles becomes greater than the width of the pinning troughs and the depinning becomes elastic with a reduced depinning threshold.

36 MATERIALS SCIENCE↗
NASA NTRS1987

Fully redundant mechanical release actuator

A system is described for performing a mechanical release function exhibiting low shock. This system includes two pyrotechnic detents fixed mounted in opposing axial alignment within a cylindrical housing having two mechanical bellows. Two mechanical bellow assemblies, each having one end hermetically bonded to the housing and the other to the respective actuator pin extending from either end of the housing, ensure that all outgassing and contamination from the operation of the pyrotechnic devices will be contained within the housing and bellows. The pin on one end of the assembly is fixed mounted and supported, via a bolt or ball-and-socket joint so that when the charge corresponding to that pin ignites, the entire assembly will exhibit rectilinear movement, including the opposing pin providing the unlatching motion. The release detent pin is supported by a linear bearing and when its corresponding pyrotechnic charge ignites the pin is retracted within the housing producing the same unlatching motion without movement of the entire assembly, thus providing complete mechanical, electrical and pyrotechnic redundancy for the unlatching pin.

Lucy, Melvin H.↗
NASA NTRS1994

AXAF SIM focus mechanism study

The design requirements and initial design concept for the AXAF-I Science Instrument Module (SIM) were reviewed at Ball on September 29, 1993. The concept design SIM focus mechanism utilizes a planetary gearset, with redundant motors, to drive a large ring (called 'main housing bearing') via a spur gearset. This large drive ring actuates three tangent bar links (called 'push rods'), which in turn actuate three levers (called 'pin levers'). Each of the three pin levers rotates an 'eccentric pin,' which in turn moves the base of a bipod flexure in both the radial (normal to optical axis) and axial (focus along optical axis) directions. Three bipod flexures are employed, equally spaced at 120 degrees apart, the base of each being translated in the two directions as described above. A focus adjustment is made by rotating the drive ring, which drives the push rods and therefore the pin levers, which in turn rotate the eccentric pins, finally imparting the two motions to the base of each of the bipod flexures. The axial translation (focus adjustment) of the focused structure is the sum of the direct axial motion plus axial motion which comes from uniformly squeezing the three bipod bases radially inward. SAO documented the following concerns regarding the focus mechanism in memo WAP-FY94-001, dated October 7, 1993: (1) The focus adjustment depends, in large part, on the structural properties (stiffnesses and end fixities) of the bipod flexures, push rods, pin levers and eccentric pins. If these properties are not matched very well, then lateral translations as well as unwanted rotations of the focussed structure will accompany focus motion. In addition, the stackup of linkage tolerances and any nonuniform wear in the linkages will result in the same unwanted motions. Thermal gradients will also affect these motions. At the review Ball did not present supporting analyses to support their choice of this design concept. (2) The proposed 'primary' method of measuring focus is by counting motor steps. The 'backup' method is by a pot mounted on the drive ring. Neither method provides for a direct measurement of the quantity desired (focus position). This is of concern because of the long and indirect relationship between focus and the sensed quantity (drive ring rotation). There are three sinusoidal relationships and structural stiffness in the path, and the resulting calibration is likely to be highly nonlinear. These methods would require an accurate ground calibration. (3) Ground calibration (and verification) of focus vs. drive position must be done in 1-g on the ground. This calibration will be complicated by both the structural characteristics of the bipods and the fact that the CG of the translating portion of the SIM is not on the optical axis (thereby causing unwated rotations and changing the focus position vs. motor step and pot readout relationships). The SIM translating weight could be offloaded, but the calibration then becomes sensitive to any errors in offloading (both magnitude and direction). There are concerns as to whether a calibration to the required accuracy can be accomplished on the ground. (4) The choice of a potentiometer as the focus position sensor is questionable in terms of reliability for a five year mission. The results of SAO's study of items 1, 2 and 3 described above are presented in this report.

Tananbaum, H. D.↗
NASA NTRS1996

Process Model for Friction Stir Welding

Friction stir welding (FSW) is a relatively new process being applied for joining of metal alloys. The process was initially developed by The Welding Institute (TWI) in Cambridge, UK. The FSW process is being investigated at NASA/MSEC as a repair/initial weld procedure for fabrication of the super-light-weight aluminum-lithium shuttle external tank. The FSW investigations at MSFC were conducted on a horizontal mill to produce butt welds of flat plate material. The weldment plates are butted together and fixed to a backing plate on the mill bed. A pin tool is placed into the tool holder of the mill spindle and rotated at approximately 400 rpm. The pin tool is then plunged into the plates such that the center of the probe lies at, one end of the line of contact, between the plates and the shoulder of the pin tool penetrates the top surface of the weldment. The weld is produced by traversing the tool along the line of contact between the plates. A lead angle allows the leading edge of the shoulder to remain above the top surface of the plate. The work presented here is the first attempt at modeling a complex phenomenon. The mechanical aspects of conducting the weld process are easily defined and the process itself is controlled by relatively few input parameters. However, in the region of the weld, plasticizing and forging of the parent material occurs. These are difficult processes to model. The model presented here addresses only variations in the radial dimension outward from the pin tool axis. Examinations of the grain structure of the weld reveal that a considerable amount of material deformation also occurs in the direction parallel to the pin tool axis of rotation, through the material thickness. In addition, measurements of the axial load on the pin tool demonstrate that the forging affect of the pin tool shoulder is an important process phenomenon. Therefore, the model needs to be expanded to account for the deformations through the material thickness and the forging affect of the shoulder. The energy balance at the boundary of the plastic region with the environment required that energy flow away from the boundary in both radial directions. One resolution to this problem may be to introduce a time dependency into the process model, allowing the energy flow to oscillate across this boundary. Finally, experimental measurements are needed to verify the concepts used here and to aid in improving the model.

Adams, Glynn↗
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.↗