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NASA NTRS1989

Current status of Joint FAA/NASA Runway Friction Program

Tests with specially instrumented NASA B-737 and FAA B-727 aircraft together with several different ground friction measuring devices have been conducted for a variety of runway surface types and wetness conditions. This effort is part of the Joint FAA/NASA Aircraft Ground Vehicle Runway Friction Program aimed at obaining a better understanding of aircraft ground handling performance under adverse weather conditions and defining relationships between aircraft and ground vehicle tire friction measurements. Aircraft braking performance on dry, wet, snow-, and ice-covered runway conditions is discussed together with ground vehicle friction data obtained under similar runway conditions. For the wet, compacted snow- and ice-covered runway conditions, the relationship between ground vehicles and aircraft friction data is identified. The influence of major test parameters on friction measurements such as speed, test tire characteristics, and surface contaminant type are discussed. The test results indicate that use of properly maintained and calibrated ground vehicles for monitoring runway friction conditions should be encouraged particularly under adverse weather conditions. The current status of the runway friction program is summarized and future test plans are identified.

Yager, Thomas J.↗

NASA NTRS1992

Friction-factor characteristics for narrow channels with honeycomb surfaces

The experimental determination of friction-factors for the flow of air in a narrow channel lined with various honeycomb geometries has been carried out. Test results show that, generally, the friction-factor is nearly constant or slightly decreases as the Reynolds number increases, a characteristic common to turbulent flow in pipes. However, in some test geometries this trend is remarkably different. The friction factor dramatically drops and then rises as the Reynolds number increases. This phenomenon can be characterized as a 'friction-factor jump'. Further investigations of the acoustic spectrum and friction-factor measurements for a broad range of Reynolds numbers indicate that the 'friction-factor jump' phenomenon is accompanied by an onset of a normal mode resonance excited coherent flow fluctuation structure, which occurs at Reynolds number of the order of 10,000. The purpose of this paper is to explain the friction-factor-jump phenomenon and friction-factor characteristics.

Ha, T. W.↗

NASA NTRS1996

A Proof of Concept Experiment for Reducing Skin Friction by Using a Micro-Blowing Technique

A proof of concept experiment for reducing skin friction has been conducted in the Advanced Nozzle and Engine Components Test Facility at the NASA Lewis Research Center. In this unique concept, called the micro-blowing technique (MBT), an extremely small amount of air was blown vertically through very small holes to reduce the surface roughness and to control the gradient of the flow velocity profile on the surface thereby reducing skin friction. Research revealed that the skin was the most important factor to make this concept achievable. The proposed skin consisted of two layers. The inner layer was a low permeable porous skin for distributing the blowing air evenly while the outer layer with small holes controlled the vertical or nearly vertical blowing air. Preliminary experimental results showed that the MBT has the potential of a very large reduction in skin friction below the skin friction of a nonporous plain flat plate. Of the skins tested, three have been identified as the MBT skins. They provided very low unblown skin friction such that a large skin friction reduction, below a flat plate value, was achieved with very small amounts of blowing air. The reduction in skin friction of 55 percent was achieved at the Mach number of 0.3 for the exhaust pressure of 0.85 atm, and 60 percent reduction was obtained for the exhaust pressure of 0.24 atm (corresponding to 10 700-m altitude) at the same Mach number. A significant reduction in skin friction of over 25 percent was achieved for the exhaust pressure of 0.24 atm at the Mach number of 0.7. This implied that the MBT could be applied to a wide range of flight conditions. It is also believed that additional 10 percent reduction could be obtained by eliminating the gap between the inner layer and the outer layer. The aspect ratio of the vertical small holes for the outer layer of the MBT skin should be larger than 4 based on the preliminary conclusion from this test. Many experiments are needed to find out the optimal MBT skin. The penalty associated with the MBT needs to be assessed. However, preliminary results indicated that the MBT could provide a 25 to 35 percent reduction for real-world application. The concept can be applied to not only an airplane, but also a missile, a submarine (micro-blow water instead of air), and an ocean liner.

Hwang, Danny P.↗

NASA NTRS2012

Damage Tolerance Assessment of Friction Pull Plug Welds

Friction stir welding is a solid state welding process developed and patented by The Welding Institute in Cambridge, England. Friction stir welding has been implemented in the aerospace industry in the fabrication of longitudinal welds in pressurized cryogenic propellant tanks. As the industry looks to implement friction stir welding in circumferential welds in pressurized cryogenic propellant tanks, techniques to close out the termination hole associated with retracting the pin tool are being evaluated. Friction pull plug welding is under development as a one means of closing out the termination hole. A friction pull plug weld placed in a friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite, plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size in the test or service environments. Test data relating residual strength capability to flaw size in two aluminum alloy friction plug weld configurations is presented.

McGill, Preston↗

NASA NTRS2012

Damage Tolerance Behavior of Friction Stir Welds in Aluminum Alloys

Friction stir welding is a solid state welding process used in the fabrication of various aerospace structures. Self-reacting and conventional friction stir welding are variations of the friction stir weld process employed in the fabrication of cryogenic propellant tanks which are classified as pressurized structure in many spaceflight vehicle architectures. In order to address damage tolerance behavior associated with friction stir welds in these safety critical structures, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data describing fracture behavior, residual strength capability, and cyclic mission life capability of friction stir welds at ambient and cryogenic temperatures have been generated and will be presented in this paper. Fracture behavior will include fracture toughness and tearing (R-curve) response of the friction stir welds. Residual strength behavior will include an evaluation of the effects of lack of penetration on conventional friction stir welds, the effects of internal defects (wormholes) on self-reacting friction stir welds, and an evaluation of the effects of fatigue cycled surface cracks on both conventional and selfreacting welds. Cyclic mission life capability will demonstrate the effects of surface crack defects on service load cycle capability. The fracture data will be used to evaluate nondestructive inspection and proof test requirements for the welds.

McGill, Preston↗

DOE OSTI2018

Analysis of Mold Friction in a Continuous Casting Using Wavelet Transform

Mold friction (MDF) is an important parameter reflecting the lubrication condition between the initial shell and the mold during continuous casting. In this article, based on practical MDF from the slab continuous casting driven by a mechanical vibration device, the characteristics of friction were analyzed by continuous wavelet transform (CWT) and discrete wavelet transform (DWT) in different casting conditions, such as normal casting, level fluctuation, and alarming of the temperature measurement system. The results show that the CWT of friction accurately captures the subtle changes in friction force, such as the periodic characteristic of MDF during normal casting and the disordered feature of MDF during level fluctuation. Most important, the results capture the occurrence of abnormal casting and display the friction frequency characteristics at this abnormal time. In addition, in this article, there are some abnormal casting conditions, and the friction signal is stable until there is a sudden large change when abnormal casting, such as split breakout and submerged entry nozzle breakage, occurs. The DWT has a good ability to capture the friction characteristics for such abnormal situations. In particular, the potential abnormal features of MDF were presented in advance, which provides strong support for identifying abnormal casting and even preventing abnormal casting.

42 ENGINEERING↗

DOE OSTI2022

Elevated temperature contact creep and friction of nickel-based superalloys using machine learning assisted finite element analysis

Nickel-based superalloys with superior thermochemical, mechanical, and tribological properties are highly utilized for critical components in several high temperature applications such as gas turbines and nuclear reactors. Inconel 617, in particular, is considered as one of the main candidate superalloys for tribo-components in very-high-temperature gas-cooled nuclear reactors. Recent findings indicate that this alloy grows unique surface oxide especially in a high-temperature helium environment with distinctive wear, friction, and contact properties. Here, this study investigates the high temperature contact area evolution and frictional behavior of Inconel 617 using finite element simulation and provides predictive models for the contact and friction performance at different normal loads, dwell times, and temperatures. High temperature helium-aged Inconel 617 top surface properties (up to 600 °C) are utilized along with a single asperity-based deformable elastic-plastic contact model under combined normal and tangential loading. Machine learning is used to assist the finite element results and to predict friction coefficient as well as contact area evolution. While a small difference is observed in the instantaneous friction coefficient (no dwell time) for all temperatures, friction coefficient increases considerably with dwell time. This shows that the effect of contact creep for longer dwell times significantly dominants the effect of high temperature variation in basic mechanical parameters such as modulus and yield strength. It is found that increasing temperature and dwell times lead to the friction coefficient increase, yet the dominance of dwell time effects decreases at higher temperatures and loads. While the analysis is presented for Inconel 617, the methodology is easy to be generalized and can be applied to other HT alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Velocity Dependence of Rate‐And‐State Friction in Granular Fault Gouge and Implications for Slow‐Slip Events

Abstract The standard rate‐and‐state friction (RSF) has extensively captured frictional behaviors, but it fails to explain the velocity dependence of frictional stability transition and widespread slow‐slip events (SSEs) in experiments and nature adequately. An alternative microphysical Chen‐Niemeijer‐Spiers (CNS) model can well describe the velocity dependence of frictional behaviors of granular gouges. Using the original CNS model, standard RSF parameters can be quantified microphysically. However, some micro‐parameters are not easy to estimate quantitatively, making it difficult to extrapolate to natural and experimental conditions. Here, we simplify the microphysically‐derived RSF parameters including direct effect a , evolution effect b , and critical slip distance D c , as well as equivalent values ( a eq , b eq , and D eq ). The simplified friction parameters directly illustrate their velocity dependence, namely the essentially constant a , a eq , and D c , negatively velocity‐dependent b and b eq , as well as varying D eq for different laws. They are roughly consistent with experimental results in various fault gouges. A modified CNS model is further derived from the original CNS model, establishing a direct link between the standard RSF and CNS models. The modified CNS model exhibits virtually identical frictional behaviors to the original CNS, but differs from the standard RSF at large velocity perturbations. Moreover, the linearized stability analysis indicates that the critical stiffness for the modified CNS model is velocity‐dependent. Compared with the standard RSF, the modified CNS model not only explains the velocity dependence of frictional stability transition, but also exhibits a more gradual transition for SSEs with a broader range of stiffness ratios.

Geochemistry & Geophysics↗

DOE OSTI2018

Effect of shape and friction on the packing and flow of granular materials

Here, the packing and flow of aspherical frictional particles are studied using discrete element simulations. Particles are superballs with shape |x| s + |y| s + |z| s = 1 that varies from sphere (s = 2) to cube (s = ∞), constructed with an overlapping-sphere model. Both packing fraction, Φ, and coordination number, z, decrease monotonically with microscopic friction μ, for all shapes. However, this decrease is more dramatic for larger s due to a reduction in the fraction of face-face contacts with increasing friction. For flowing grains, the dynamic friction ~μ —the ratio of shear to normal stresses—depends on shape, microscopic friction, and inertial number I . For all shapes, ˜μ grows from its quasistatic value ˜μ 0 as (˜μ - ˜μ 0 ) = dI α , with different universal behavior for frictional and frictionless shapes. For frictionless shapes the exponent α ≈ 0.5 and prefactor d ≈ 5˜μ 0 while for frictional shapes α ≈ 1 and d varies only slightly. Lastly, the results highlight that the flow exponents are universal and are consistent for all the shapes simulated here.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Experimental Study on the Effect of Localized Blockages on the Friction Factor of a 61-Pin Wire-Wrapped Bundle

Abstract The thermal-hydraulic behavior of the flow in rod bundles has motivated numerous experimental and computational investigations. Previous studies have identified potential for accumulation of debris within the small subchannels of typical wire-wrapped assemblies with subsequent total or partial blockage of subchannel coolant flow. A test campaign was conducted to study the effects of localized blockages on the bundle averaged friction factor of a tightly packed wire-wrapped rod bundle. Blockages were installed within the bundle, and fluid pressure drop was measured across one wire pitch for a Reynolds number range of 500–17,200. The Darcy–Weisbach friction factor of the perturbed rod bundle geometry was compared with that of the unblocked bundle, as well as with the predictions of a well-established friction factor correlation. Differing effects based on blockage size and location for various flow regimes were studied. A number of conclusions can be made about the effects of the blockages on the friction factor, such as an increasing effect of the blockage on friction factor with an increase in Reynolds number, a change in flow behavior in the turbulent transition flow regime near Reynolds number 3000, differences in effect on friction factor for different types of subchannel blockage, and a nonlinear trend in friction factor variation with flow area impeded for edge subchannels. To this end, all data and quantified uncertainty produced in this study are made available for comparison and validation of advanced computational tools.

Engineering↗

DOE OSTI2022

Computation of Direct Sensitivities of Spatial Multibody Systems With Joint Friction

Abstract Friction exists in most mechanical systems and may have a major influence on the dynamic performance of the system. The incorporation of friction in dynamic systems has been a subject of active research for several years owing to its high nonlinearity and its dependence on several parameters. Consequently, optimization of dynamic systems with friction becomes a challenging task. Gradient-based optimization of dynamical systems is a prominent technique for optimal design and requires the computation of model sensitivities with respect to the design parameters. The novel contribution of this paper is the derivation of the analytical methodology for the computation of direct sensitivities for smooth multibody systems with joint friction using the Lagrangian index-1 formulation. System dynamics have been computed using two different friction models; the Brown and McPhee, and the Gonthier et al. model. The methodology proposed to obtain model sensitivities has also been validated using the complex finite difference method. A case study has been conducted on a spatial multibody system to observe the effect of friction on the dynamics and model sensitivities, compare sensitivities with respect to different parameters and demonstrate the numerical and validation aspects. Since design parameters can have very different magnitudes and units, the sensitivities have been scaled with the parameters for comparison. Finally, a discussion has been presented on the interpretation of the case study results. Due to the incorporation of joint friction, ‘jumps’ or discontinuities are observed in the model sensitivities akin to those observed for hybrid dynamical systems.

Engineering↗

NASA NTRS1972

Friction welding.

Results of an exploratory study of the structure and properties of friction welds in Udimet 700 (U-700) and TD-nickel (TD-Ni) bar materials, as well as dissimilar U-700/TD-Ni friction welds. Butt welds were prepared by friction welding 12.7-mm-diam U-700 bars and TD-Ni bars. Specimens for elevated temperature tensile and stress rupture testing were machined after a postweld heat treatment. Friction welding of U-700 shows great potential because the welds were found to be as strong as the parent metal in stress rupture and tensile tests at 760 and 980 C. In addition, the weld line was not detectable by metallographic examination after postheating. Friction welds in TD-Ni or between U-700 and TD-Ni were extremely weak at elevated temperatures. The TD-Ni friction welds could support only 9% as much stress as the base metal for 10-hour stress rupture life at 1090 C. The U-700/TD-Ni weld could sustain only 15% as much stress as the TD-Ni parent metal for a 10-hour stress rupture life at 930 C. Thus friction welding is not a suitable joining method for obtaining high-strength TD-Ni or U-700/TD-Ni weldments.

Moore, T. J.↗

NASA NTRS1976

Friction of iron lubricated with aliphatic and aromatic hydrocarbons and halogenated analogs

The influence of oxygen and various organic molecules on the reduction of the friction of an iron (011) single crystal surface was investigated. A comparison was made between aliphatic and aromatic structures, all of which contained six carbon atoms, and among various halogen atoms. Results of the investigation indicate that hexane and benzene give similar friction coefficients over a range of loads except at very light loads. At light loads, the friction decreased with an increase in the load where the halogens fluorine and chlorine are incorporated into the benzene molecular structure; however, over the same load range when bromine and iodine were present, the friction was relatively unchanged. The aliphatic compound chlorohexane exhibited lower friction coefficients than the aromatic structure chlorobenzene at very light loads. With the brominated benzene structures, however, friction was essentially the same. Oxygen was more effective in reducing friction than were the simple hydrocarbons.

Buckley, D. H.↗

NASA NTRS1984

Water-vapor effects on friction of magnetic tape in contact with nickel-zinc ferrite

The effects of humidity of moist nitrogen on the friction and deformation behavior of magnetic tape in contact with a nickel-zinc ferrite spherical pin were studied. The results indicate that the coefficient of friction is markedly dependent on the ambient relative humidity. Although the coefficient of friction remains low below 40-percent relative humidity, it increases rapidly with increasing relative humidity above 40 percent. The general ambient environment of the tape does not have any effect on the friction behavior if the area where the tape is in sliding contact with the ferrite pin is flooded with controlled nitrogen. The response time for the friction of the tape to humidity changes is about 10 sec. The effect of friction as a function of relative humidity on dehumidifying is very similar to that on humidifying. A surface softening of the tape due to water vapor increases the friction of the tape.

Miyoshi, K.↗

NASA NTRS1984

The Influence of Surface Topography on Polymer Friction

Current friction models for polymers are examined to determine their applicability in predicting the effects of roughness on friction. The two component, adhesion deformation model of friction predicts the variation of friction with the change in the sliding direction with respect to the lay direction on anisotropic rough surfaces. The two component model does not predict the change in friction with changes in roughness. A combination of an energy based model and a slip line deformation model may provide a friction model which could better represent measured friction.

Eiss, N. S., Jr.↗

NASA NTRS1984

Transient Response Dynamic Module Modifications to Include Static and Kinetic Friction Effects

A methodology that supports forced transient response dynamic solutions when both static and kinetic friction effects are included in a structural system model is described. Modifications that support this type of nonlinear transient response solution are summarized for the transient response dynamics (TRD) NASTRAN module. An overview of specific modifications for the NASTRAN processing subroutines, INITL, TRD1C, and TRD1D, are described with further details regarding inspection of nonlinear input definitions to define the type of nonlinear solution required, along with additional initialization requirements and specific calculation subroutines to successfully solve the transient response problem. The extension of the basic NASTRAN nonlinear methodology is presented through several stages of development to the point where constraint equations and residual flexibility effects are introduced into the finite difference Newmark-Beta recurrsion formulas. Particular emphasis is placed on cost effective solutions for large finite element models such as the Space Shuttle with friction degrees of freedom between the orbiter and payloads mounted in the cargo bay. An alteration to the dynamic finite difference equations of motion is discussed, which allows one to include friction effects at reasonable cost for large structural systems such as the Space Shuttle. Data are presented to indicate the possible impact of transient friction loads to the payload designer for the Space Shuttle. Transient response solution data are also included, which compare solutions without friction forces and those with friction forces for payloads mounted in the Space Shuttle cargo bay. These data indicate that payload components can be sensitive to friction induced loads.

Misel, J. E.↗

NASA NTRS1989

Aircraft and ground vehicle friction measurements obtained under winter runway conditions

Tests with specially instrumented NASA B-737 and B-727 aircraft together with several different ground friction measuring devices have been conducted for a variety of runway surface types and wetness conditions. This effort is part of the Joint FAA/NASA Aircraft/Ground Vehicle Runway Friction Program aimed at obtaining a better understanding of aircraft ground handling performance under adverse weather conditions, and defining relationships between aircraft and ground vehicle tire friction measurements. Aircraft braking performance on dry, wet, snow-, and ice-covered runway conditions is discussed together with ground vehicle friction data obtained under similar runway conditions. For the wet, compacted snow- and ice-covered runway conditions, the relationship between ground vehicles and aircraft friction data is identified. The influence of major test parameters on friction measurements such as speed, test tire characteristics, and surface contaminant-type are discussed. The test results indicate that use of properly maintained and calibrated ground vehicles for monitoring runway friction conditions should be encouraged particularly under adverse weather conditions.

Yager, Thomas J.↗

NASA NTRS1993

Friction and wear of plasma-deposited diamond films

Reciprocating sliding friction experiments in humid air and in dry nitrogen and unidirectional sliding friction experiments in ultrahigh vacuum were conducted with a natural diamond pin in contact with microwave-plasma-deposited diamond films. Diamond films with a surface roughness (R rms) ranging from 15 to 160 nm were produced by microwave-plasma-assisted chemical vapor deposition. In humid air and in dry nitrogen, abrasion occurred when the diamond pin made grooves in the surfaces of diamond films, and thus the initial coefficients of friction increased with increasing initial surface roughness. The equilibrium coefficients of friction were independent of the initial surface roughness of the diamond films. In vacuum the friction for diamond films contacting a diamond pin arose primarily from adhesion between the sliding surfaces. In these cases, the initial and equilibrium coefficients of friction were independent of the initial surface roughness of the diamond films. The equilibrium coefficients of friction were 0.02 to 0.04 in humid air and in dry nitrogen, but 1.5 to 1.8 in vacuum. The wear factor of the diamond films depended on the initial surface roughness, regardless of environment; it increased with increasing initial surface roughness. The wear factors were considerably higher in vacuum than in humid air and in dry nitrogen.

Miyoshi, Kazuhisa↗