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At least 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

Further Developments of the Fringe-Imaging Skin Friction Technique

Various aspects and extensions of the Fringe-Imaging Skin Friction technique (FISF) have been explored through the use of several benchtop experiments and modeling. The technique has been extended to handle three-dimensional flow fields with mild shear gradients. The optical and imaging system has been refined and a PC-based application has been written that has made it possible to obtain high resolution skin friction field measurements in a reasonable period of time. The improved method was tested on a wingtip and compared with Navier-Stokes computations. Additionally, a general approach to interferogram-fringe spacing analysis has been developed that should have applications in other areas of interferometry. A detailed error analysis of the FISF technique is also included.

Zilliac, Gregory C.↗
NASA NTRS1998

Friction Stir Weld Tooling Development for Application on the 2195 Al-Cu-Li Space Transportation System External Tank

Friction Stir Welding (FSW) is a new and innovative solid-state joining process which can be applied to difficult-to- weld aluminum alloys. However, the large forces involved with the process have posed a production tooling challenge. Lockheed Martin Michoud Space Systems has overcome many of these challenges on the Super Lightweight External Tank (ET) program. Utilizing Aluminum-Copper-Lithium alloy 2195 in the form of plate and extrusions, investigations of FSW process parameters have been completed. Major loading mechanisms are discussed in conjunction with deflection measurements. Since the ET program is a cryogenic application, a brief comparison of cryogenic material properties with room temperature material properties is offered for both FSW and fusion welds. Finally, a new approach to controlling the FSW process from a load perspective is introduced. Emphasis will be put on tooling development, as well as the impact of tooling design and philosophy on Friction Stir Weld success probability.

Loftus, Zachary↗
NASA NTRS1960

Friction and Pressure Drag of Boundary-Layer Diverter Systems at Mach Number of 3.0

An experimental investigation was performed at a Mach number of 3.0 to determine the friction and pressure drags of a pylon and a 20 deg- and a 40 deg-included-angle wedge diverter over a range of Reynolds number. The results indicated that the measured friction drag coefficients agreed reasonably with that predicted by flat-plate theory. The pressure drag coefficients of the 20 and 40 deg wedges agreed with those presented in the literature. The total drag coefficient of the pylon and the 20 deg wedge diverter was about 0.36, based on diverter frontal area, while the drag coefficient of the 40 deg wedge was about 0.47.

Stitt, Leonard E.↗
NASA NTRS1961

Effect of Inert, Reducing, and Oxidizing Atmospheres on Friction and Wear of Metals to 1000 F

Experiments were conducted in inert, reducing, and oxidizing atmospheres to determine their influence on the friction and wear properties of various metals. Nitrogen, argon, forming gas (10 volume percent H2, 90 volume percent N2), and various concentrations of oxygen in nitrogen were used. A 3/16-inch-radius hemispherical rider under a load of 1000 grams contacted the flat surface of a rotating disk. The surface speed employed was 35 feet per minute. The presence of surface oxides is vitally important to the protection of metals in sliding contact. Extremely high friction and excessive wear were encountered in the absence of these oxides. In some instances (electrolytically pure copper), the removal of the surface oxides resulted in mass welding of the specimens in sliding contact. Extremely small quantities of oxygen are sufficient to provide protection of metal surfaces; for example, with 440-C stainless steel, 0.03 volume percent oxygen was found to be adequate.

Buckley, Donald H.↗
NASA NTRS1958

Heat-Transfer and Friction Measurements with Variable Properties for Airflow Normal to Finned and Unfinned Tube Banks

A single-line correlation of both the heat-transfer and pressure- drop data for electrically heated unfinned tubes is obtained by evaluating the density in the Reynolds number, specific heat, thermal conductivity, and viscosity at the film temperature, and the density in the friction coefficient at the bulk temperature. The heat-transfer data for finned tubes also exhibit an effect of physical-property variation which is removed by evaluating all properties, including density, at the primary surface temperature, and using k* = 0.015 square root of T/530 for the thermal conductivity of air where T is the absolute temperature. The pressure drop for finned tubes is correlated by the use of bulk density in both the Reynolds number and friction coefficient. The data reported are for Reynolds numbers from 2000 to 35,000, surface temperatures from 600 to 1400 R, and an air inlet temperature of 530 R.

Ragsdale, Robert G.↗
NASA NTRS1959

Use of a Stanton Tube for Skin-Friction Measurements

A small total-pressure tube resting against a flat-plate surface was used as a Stanton tube and calibrated as a skin-friction meter at various subsonic and supersonic speeds. Laminar flow was maintained for the supersonic runs at a Mach number M(sub infinity) of 2. At speeds between M(sub infinity) = 1.33 and M(sub infinity) = 1.87, the calibrations were carried-out in a turbulent boundary layer. The subsonic flows were found to be in transition. The skin-friction readings of a floating-element type of balance served as the reference values against which the Stanton tube was calibrated. A theoretical model was developed which, for moderate values of the shear parameter tau, accurately predicts the performance of the Stanton tube in subsonic and supersonic flows. A "shear correction factor" was found to explain the deviations from the basic model when T became too large. Compressibility effects were important only in the case of turbulent supersonic flows, and they did not alter the form of the calibration curve. The test Reynolds numbers, based on the distance from the leading edge and free-stream conditions, ranged from 70,000 to 875,000. The turbulent-boundary-layer Reynolds numbers, based on momentum thickness, varied between 650 and 2,300. Both laminar and turbulent velocity profiles were taken and the effect of pressure gradient on the calibration was investigated.

Abarbanel, S. S.↗
NASA NTRS1959

Investigation of the Maximum Spin-Up Coefficients of Friction Obtained During Tests of a Landing Gear Having a Static-Load Rating of 20,000 Pounds

An experimental investigation was made at the Langley landing loads track to obtain data on the maximum spin-up coefficients of friction developed by a landing gear having a static-load rating of 20,000 pounds. The forward speeds ranged from 0 to approximately 180 feet per second and the sinking speeds, from 2.7 feet per second to 9.4 feet per second. The results indicated the variation of the maximum spin-up coefficient of friction with forward speed and vertical load. Data obtained during this investigation are also compared with some results previously obtained for nonrolling tires to show the effect of forward speed.

Batterson, Sidney A.↗
NASA NTRS1998

Loading Considerations for Implementing Friction STIR Welding for Large Diameter Tank Fabrication

The main objectives of the research presented here are to determine the reaction loads associated with friction stir welding (FSW) and to determine the suitability of an existing welding fixture for implementing this welding process in the fabrication of large diameter tanks. Friction stir welding is a relatively new process which is being investigated as a method for joining aluminum alloys. The aluminum-lithium alloy, Al-Li 2195, which is being used to fabricate the super-light-weight shuttle external tank has proven difficult to join using fusion techniques. Therefore, FSW and its potential applicability to joining Al-Li 2195 are of particular interest to NASA.

Adams, Glynn↗
NASA NTRS1998

Mechanistic Models of Friction Stir Welding

Friction stir welding is a welding process developed at The Welding Institute (TWI) in England. The method uses very large strain plastic deformation of the material to join two pieces of metal together. The material is deformed using a tool which is forced between the two pieces which rotates causing a bond. Beyond this, very little is actually known although many people working in the field are willing to speculate on the detailed mechanisms involved. Some measurements made using sacrificial thermocouples at the weld joint indicate that the maximum temperature during the weld process is on the order of 370C - well below the melting temperature of the material. However, at this temperature, the material properties are highly temperature dependent, and the yield stress is approximately an order of magnitude less at this temperature than it is at room temperature. As expected, there are many interpretations of the physical mechanisms occurring during the weld process. Although there is very little published concerned with FSW, some of the anecdotal theories will be described. One describes the primary mechanism as frictional heating at the front of the tool caused by slip between the tool and the material. At elevated temperatures, the weld material becomes soft and deforms around the tool but not essentially altered by the tool rotation, similar to an extrusion. As the material meets again at the rear of the tool, the temperatures and pressures are sufficient to cause the material to bond. All other structures seen are secondary and unimportant. Another theory examined last summer at NASA's Marshall Space Flight Center (MSFC) was that there was no slip between the tool and the material resulting in a rotating mass of plastic weld material traveling at a variety of angular velocities - the greatest at the tool surface diminishing to zero at the outer edge of the plastic mass surrounding the tool. This conceptual model was followed by simplified calculations which showed that the balance of moments through the weld plug was not possible under steady state conditions and realistic temperature profiles. This led to some consideration of a quasi-steady oscillating process. Later when force measurements became available some models were modified and new ones were proposed.

Stewart, Michael B.↗
NASA NTRS1994

Friction Factor for Flow in Rectangular Ducts with One Side Rib-Roughened

Numerical simulations of incompressible turbulent flow through rectangular ducts with one side rib-roughened were performed to determine pressure drop. The "PHOENICS " software package was used for the computations, which required provision of a wall function for transverse rib-roughened surfaces. The present study was conducted in the range of 10(exp 5) less than or equal to Reynolds number less than or equal to 10(exp 7), 0.01 less than or equal to rib height to hydraulic diameter ratio less than or equal to 0.04, 10 less than or equal to pitch to rib height ratio less than or equal to 40. Using the numerical results, friction factor charts for various aspect ratios were generated. The numerical results agreed well with experimental data that was obtained for 10(exp 5) less than Reynolds less than 2 x 10(exp 5). In addition, a scheme for predicting friction factor using existing correlations for smooth and rough walls was developed.

Youn, B.↗
NASA NTRS1999

Friction Stir Welding of SiC/Aluminum Metal Matrix Composites

Friction Stir Welding (FSW) is a new solid state process for joining metals by plasticizing and consolidating materials around the bond line using thermal energy producing from frictional forces. A feasibility study for FSW of Metal Matrix Composites (MMC) was investigated using aluminum 6092 alloy reinforced with 17% SiC particulates. FSW process consists of a special rotating pin tool that is positioned to plunge into the MMC surface at the bond line. As the tool rotates and move forward along the bond line, the material at the bond line is heated up and forced to flow around the rotating tip to consolidate on the tip's backside to form a solid state joint. FSW has the potential for producing sound welds with MMC because the processing temperature occurs well below the melting point of the metal matrix; thereby eliminating the reinforcement-to-matrix solidification defects, reducing the undesirable chemical reactions and porosity problems.

Lee, Jonathan A.↗
NASA NTRS1999

Diffusion, Fluxes, Friction Forces, and Joule Heating in Two-Temperature Multicomponent Magnetohydrodynamics

The relationship between Joule heating, diffusion fluxes, and friction forces has been studied for both total and electron thermal energy equations, using general expressions for multicomponent diffusion in two-temperature plasmas with the velocity dependent Lorentz force acting on charged species in a magnetic field. It is shown that the derivation of Joule heating terms requires both diffusion fluxes and friction between species which represents the resistance experienced by the species moving at different relative velocities. It is also shown that the familiar Joule heating term in the electron thermal energy equation includes artificial effects produced by switching the convective velocity from the species velocity to the mass-weighted velocity, and thus should not be ignored even when there is no net energy dissipation.

Chang, C. H.↗
NASA NTRS1999

Mechanical Property Analysis in the Retracted Pin-Tool (RPT) Region of Friction Stir Welded (FSW) Aluminum Lithium 2195

The "Auto-Adjustable Pin Tool for Friction Stir Welding", was developed at The Marshall Space Flight Center to address process deficiencies unique to the FSW process. The auto-adjustable pin tool, also called the retractable pin-tool (R.PT) automatically withdraws the welding probe of the pin-tool into the pin-tool's shoulder. The primary function of the auto-adjustable pin-tool is to allow for keyhole closeout, necessary for circumferential welding and localized weld repair, and, automated pin-length adjustment for the welding of tapered material thickness. An overview of the RPT hardware is presented. The paper follows with studies conducted using the RPT. The RPT was used to simulate two capabilities; welding tapered material thickness and closing out the keyhole in a circumferential weld. The retracted pin-tool regions in aluminum- lithium 2195 friction stir weldments were studied through mechanical property testing and metallurgical sectioning. Correlation's can be =de between retractable pin-tool programmed parameters, process parameters, microstructure, and resulting weld quality.

Ding, R. Jeffrey↗
NASA NTRS1998

Friction Stir Welding of Large Scale Cryogenic Tanks for Aerospace Applications

The Marshall Space Flight Center (MSFC) has established a facility for the joining of large-scale aluminum cryogenic propellant tanks using the friction stir welding process. Longitudinal welds, approximately five meters in length, have been made by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and travel system will be described in this presentation along with process controls and real-time data acquisition developed for this application. The approach to retrofitting other large welding tools at MSFC with the friction stir welding process will also be discussed.

Russell, Carolyn↗
NASA NTRS1999

Overflow: Facts on Friction

This paper presents results of three minor studies into the behavior of the OVERFLOW with respect to the prediction of skin friction drag on wing bodies at cruise Mach number and wind tunnel Reynolds number. The studies include a preliminary assessment of the behavior of the two new 2-equation turbulence models introduced with the latest version of OVERFLOW (v. 1.8f), an investigation into potential improvements in the matrix dissipation scheme currently implemented in OVERFLOW, and an analysis of the observed sensitivity of the code's skin friction predictions to grid stretching at solid surface boundaries.

Lawrence, Scott↗
NASA NTRS2000

Lack of Penetration in Friction Stir Welds: Effects on Mechanical Properties and NDE Feasibility

This presentation reviews the issue of lack of penetration (LOP) in Friction Stir Welding and the feasibility of using non-destructive tests to detect . Friction Stir Welding takes place in the solid phase below the melting point of the materials to be joined. It thus gives the ability to join materials which are difficult to fusion weld, for example 2000 and 7000 aluminium alloys. This process though can result in a lack of penetration, due to an incomplete penetration of the DXZ. This is frequently referred to as a "kissing bond", which requires micro examination to detect. The presentation then discusses the surface crack tension tests. It then reviews the simulated service test and results. It then discusses the feasibility of using non-destructive examination to detect LOP, the forms of test which can be used, and the results the tests.

Kinchen, David G.↗
NASA NTRS2001

Wiping Metal Transfer in Friction Stir Welding

Much evidence suggests that as the friction stir pin-tool moves along a weld seam the displacement of metal takes place by a wiping action at the surface of a plug of metal that rotates with the tool. The wiping model is explained and some consequences for the friction stir welding process are drawn.

Nunes, Arthur C., Jr.↗