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At least 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Environmental fatigue of an Al-Li-Cu alloy. Part 2: Microscopic hydrogen cracking processes

Based on a fractographic analysis of fatigue crack propagation (FCP) in Al-Li-Cu alloy 2090 stressed in a variety of inert and embrittling environments, microscopic crack paths are identified and correlated with intrinsic da/dN-delta K kinetics. FCP rates in 2090 are accelerated by hydrogen producing environments (pure water vapor, moist air, and aqueous NaCl), as defined in Part 1. For these cases, subgrain boundary fatigue cracking (SGC) dominates for delta K values where the crack tip process zone, a significant fraction of the cyclic plastic zone, is sufficiently large to envelop 5 micron subgrains in the unrecrystallized microstructure. SGC may be due to strong hydrogen trapping at T1 precipitates concentrated at sub-boundaries. At low delta K, the plastic zone diameter is smaller than the subgrain size and FCP progresses along (100) planes due to either local lattice decohesion or aluminum-lithium hydride cracking. For inert environments (vacuum, helium, and oxygen), or at high delta K where the hydrogen effect on da/dN is small, FCP is along (111) slip planes; this mode does not transition with increasing delta K and plastic zone size. The SGC and (100) crystallographic cracking modes, and the governing influence of the crack tip process zone volume (delta K), support hydrogen embrittlement rather than a surface film rupture and anodic dissolution mechanism for environmental FCP. Multi-sloped log da/dN-log delta K behavior is produced by changes in process zone hydrogen-microstructure interactions, and not by purely micromechanical-microstructure interactions, in contradiction to microstructural distance-based fatigue models.

Robert S Piascik↗
NASA NTRS1992

Finite-element analyses and fracture simulation in thin-sheet aluminum alloy

A two-dimensional, elastic-plastic finite-element analysis was used with a critical crack-tip-opening angle (CTOA) fracture criterion to model stable crack growth in thin-sheet 2024-T3 aluminum alloy under monotonic loading after precracking at different cyclic stress levels. Tests were conducted on three types of specimens: middle-crack, three-hole-crack and blunt-notch tensile specimens. An experiment technique was developed to measure CTOA during crack growth initiation and stable tearing using a high-resolution video camera and recorder. Crack front shapes were also measured during initiation and stable tearing using a fatigue marker-load technique. Three-dimensional elastic-plastic finite-element analyses of these crack shapes for stationary cracks were conducted to study the crack-front opening displacements. Predicted load against crack extension on middle-crack tension specimens agreed well with test results even for large-scale plastic deformations. The analyses were able to predict the effects of specimen size and precracking stress history on stable tearing. Predicted load against load-line displacements agreed well with test results up to maximum load bu the analyses tended to overpredict displacements as crack grew beyond the maximum load under displacement-controlled conditions. During the initiation phase, the measured CTOA values were high but decreased and remained nearly constant after a small amount of stable tearing. The constant value of CTOA agree well with the calculated value from the finite-element analysis. The larger CTOA values measured at the sheet surface during the initiation phase may be associated with the crack tunneling observed in the tests. Three-dimensional analyses for nonstraight crack fronts predicted much higher displacements near the free surface than in the interior.

Newman, J. C., Jr.↗
NASA NTRS1992

Effects of constraint on crack growth under aircraft spectrum loading

The objective is to study the effects of constraint on fatigue crack growth under aircraft spectrum loading. A plasticity-induced crack-closure model that accounts for constraint variations during the transition from flat-to-slant crack growth was used to correlate crack-growth rate data under constant-amplitude loading and to calculate crack growth under simulated aircraft spectrum loading. The model was applied to several thin-sheet aluminum alloy materials. Under laboratory air conditions, the transition was shown to be related to the size of the cyclic plastic zone based on the effective stress-intensity factor range for several sheet materials and thicknesses. Results from three-dimensional, elastic-plastic, finite-element analyses of a flat, straight-through crack in a thin-sheet aluminum alloy specimen showed a constraint loss similar to that assumed in the model. Using test data and the closure model, the location of the constraint-loss regime in terms of growth rate and the value of the constraint factor at these rates were determined by trial and error. The model was then used to calculate crack growth under the TWIST spectrum. The calculated results agreed reasonably well with test data. In general, the model predicted shorter crack-growth lives than tests under the TWIST spectrum by about 40 percent. For the TWIST spectrum clipped at Level 3, the calculated lives were within about 20 percent. The results demonstrated that constraint variations, especially for thin-sheet alloys, should be accounted for to predict crack growth under typical aircraft spectra.

Newman, J. C., Jr.↗
NASA NTRS1993

Growth Of Fatigue Cracks In An Aluminum Alloy

Report discusses application of mathematical crack-closure model to study growth of cracks under various load histories. Model based on crack-tip-plasticity concept, modified to leave plastically deformed material in wake of advancing crack tip. Effect of thickness of material on plasticity accounted for by using "constraint" factor in connection with tensile yielding at crack tip.

Newman, J. C., Jr.↗
NASA NTRS1993

Low cycle fatigue behavior of polycrystalline NiAl at 300 and 1000 K

The low cycle fatigue behavior of polycrystalline NiAl was determined at 300 and 1000 K - temperatures below and above the brittle- to-ductile transition temperature (BDTT). Fully reversed, plastic strain-controlled fatigue tests were conducted on two differently fabricated alloy samples: hot isostatically pressed (HIP'ed) prealloyed powder and hot extruded castings. HIP'ed powder (HP) samples were tested only at 1000 K, whereas the more ductile cast-and-extruded (C+E) NiAl samples were tested at both 1000 and 300 K. Plastic strain ranges of 0.06 to 0.2 percent were used. The C+E NiAl cyclically hardened until fracture, reaching stress levels approximately 60 percent greater than the ultimate tensile strength of the alloy. Compared on a strain basis, NiAl had a much longer fatigue life than other B2 ordered compounds in which fracture initiated at processing-related defects. These defects controlled fatigue life at 300 K, with fracture occurring rapidly once a critical stress level was reached. At 1000 K, above the BDTT, both the C+E and HP samples cyclically softened during most of the fatigue tests in air and were insensitive to processing defects. The processing method did not have a major effect on fatigue life; the lives of the HP samples were about a factor of three shorter than the C+E NiAl, but this was attributed to the lower stress response of the C+E material. The C+E NiAl underwent dynamic grain growth, whereas the HP material maintained a constant grain size during testing. In both materials, fatigue life was controlled by intergranular cavitation and creep processes, which led to fatigue crack growth that was primarily intergranular in nature. Final fracture by overload was transgranular in nature. Also, HP samples tested in vacuum had a life three times longer than their counterparts tested in air and, in contrast to those tested in air, hardened continuously over half of the sample life, thereby indicating an environmentally assisted fatigue damage mechanism. The C+E samples were tested only in air. At 1000 K, NiAl exhibited a superior fatigue life when compared to most superalloys on a plastic strain basis, but was inferior to most superalloys on a stress basis.

Lerch, Bradley A.↗
NASA NTRS1991

Deformation and failure mechanisms in metal matrix composites

An investigation was undertaken to determine the key deformation mechanisms and their interaction leading to failure of both 0 degree and 90 degree Ti 15-3/SCS-6 laminae under monotonic loading. The experimental results suggest that inelastic deformation in the 0-degree lamina is dominated by plastic deformation and that in the 90-degree lamina is dominated by both fiber-matrix debonding and plasticity. The loading-unloading response, monitoring of Poisson's ratio and microscopy were utilized to identify the key deformation mechanisms. The sequence of deformation mechanisms leading to failure are identified for both the 0 and the 90-degree specimens. The threshold strains for plasticity or damage which are referred to as 'microdeformation' in the 0 deg and 90 deg laminae are approximately 0.004 and 0.002, respectively, at room temperature. These strain levels may be considered critical in initiation based structural design with these composites.

Newaz, G.↗
NASA NTRS1947

Elastic Properties in Tension and Shear of High Strength Nonferrous Metals and Stainless Steel - Effect of Previous Deformation and Heat Treatment

A resume is given of an investigation of the influence of plastic deformation and of annealing temperature on the tensile and shear elastic properties of high strength nonferrous metals and stainless steels in the form of rods and tubes. The data were obtained from earlier technical reports and notes, and from unpublished work in this investigation. There are also included data obtained from published and unpublished work performed on an independent investigation. The rod materials, namely, nickel, monel, inconel, copper, 13:2 Cr-Ni steel, and 18:8 Cr-Ni steel, were tested in tension; 18:8 Cr-Ni steel tubes were tested in shear, and nickel, monel, aluminum-monel, and Inconel tubes were tested in both tension and shear. There are first described experiments on the relationship between hysteresis and creep, as obtained with repeated cyclic stressing of annealed stainless steel specimens over a constant load range. These tests, which preceded the measurements of elastic properties, assisted in devising the loading time schedule used in such measurements. From corrected stress-set curves are derived the five proof stresses used as indices of elastic or yield strength. From corrected stress-strain curves are derived the secant modulus and its variation with stress. The relationship between the forms of the stress-set and stress-strain curves and the values of the properties derived is discussed. Curves of variation of proof stress and modulus with prior extension, as obtained with single rod specimens, consist in wavelike basic curves with superposed oscillations due to differences of rest interval and extension spacing; the effects of these differences are studied. Oscillations of proof stress and modulus are generally opposite in manner. The use of a series of tubular specimens corresponding to different amounts of prior extension of cold reduction gave curves almost devoid of oscillation since the effects of variation of rest interval and extension spacing were removed. Comparison is also obtained between the variation of the several properties, as measured in tension and in shear. The rise of proof stress with extension is studied, and the work-hardening rates of the various metals evaluated. The ratio between the tensile and shear proof stresses for the various annealed and cold-worked tubular metals is likewise calculated. The influence of annealing or tempering temperature on the proof stresses and moduli for the cold-worked metals and for air-hardened 13:2 Cr-Ni steel is investigated. An improvement of elastic strength generally is obtained, without important loss of yield strength, by annealing at suitable temperature. The variation of the proof stress and modulus of elasticity with plastic deformation or annealing temperature is explained in terms of the relative dominance of three important factors: namely, (a) internal stress, (b) lattice-expansion or work-hardening, and (c) crystal reorientation. Effective values of Poisson's ratio were computed from tensile and shear moduli obtained on tubular specimens. The variation of Poisson's ratio with plastic deformation and annealing temperature is explained in terms of the degree of anisotropy produced by changes of (a) internal stress and (b) crystal orientation.

METALS - ELASTICITY↗
NASA NTRS1993

Prediction of stable tearing of 2024-T3 aluminum alloy using the crack-tip opening angle approach

In this study, the crack-tip opening angle (CTOA) approach was incorporated into a damage growth finite element program, MADGIC (Micromechanics Analysis and Damage Growth in Composites), and was used to predict stable tearing in a middle-crack tension 2024-T3 aluminum alloy specimen. The MADGIC code is a displacement based finite element program implemented with an incremental elastic-plastic algorithm used to model elastic-plastic behavior and a nodal splitting and nodal force relaxation algorithm used to generate crack surfaces. Predictions of the applied stress as a function of crack extension and applied stress as a function of load-line displacement were in good agreement with experiments and with similar predictions made using an existing finite element program, ZIP2D. In addition, path integrals, namely, the J-integral and T*-integral, were also evaluated and compared with the CTOA approach. There appears to be a weak relationship between the CTOA and the T*-integral evaluated on a specific integration path during crack extension beyond maximum applied stress. This study further verifies that the CTOA can be used as an effective elastic-plastic fracture mechanics parameter to predict crack growth.

Bakuckas, J. G., Jr.↗
NASA NTRS1993

Mold bolt and means for achieving close tolerances between bolts and bolt holes

In the space shuttle, a cargo bay storage rack was required which was to be manufactured from a metal-plastic composite and bolted to a cargo structure. Following completion, utilization of the rack was disallowed due to tolerances, that is, the size differences between the outside bolt diameter and the inside hole diameter. In addition to the space shuttle problem there are other close tolerance requirements for bolts. Such environments often benefit from close tolerance bolting. Frequently such fabrication is not cost effective. Consequently there is a need for means of achieving close tolerances between bolts and bolt holes. Such means are provided. After compressing the elements together a strong rigid plastic, ceramic, or ceramic plastic fluid is forced into a channel extending through the bolt.

Johnston, David L.↗
NASA NTRS1994

Microscale synthesis and characterization of polystyrene: NSF-POLYED scholars project

Polystyrene is a familiar polymer with many commercial uses. Its applications range from the clear, high index of refraction, brittle plastic used to form audio cassette and CD cases to the foamed material used in insulated drink cups and packaging material. Polystyrene constitutes 11 percent of the plastics used in packaging with only High Density Polyethylene (HDPE) and Low Density Polyethylene (LDPE) contributing a larger share: so much polystyrene is used today, it is one of six common plastics that manufacturers have assigned an identification code. The code helps recycling efforts. Polystyrene's code is (PS code 6). During the summer and fall of 1992 several new polymeric experiments were developed by the NSF POLYED Scholars for introduction into the chemistry core curriculum. In this presentation, one such project will be discussed. This laboratory project is recommended for a first or second year laboratory course allowing the introduction of polymeric science to undergraduates at the earliest opportunity. The reliability of the experiments which make up this project and the recognition factor of polystyrene, a material we come in contact with everyday, makes the synthesis and characterization of polystyrene a good choice for the introduction of polymerization to undergraduates. This laboratory project appeals to the varied interests of students enrolled in the typical first year chemistry course and becomes an ideal way to introduce polymers to a wide variety of science and engineering students.

Quaal, Karen S.↗
NASA NTRS1994

A coupled/uncoupled deformation and fatigue damage algorithm utilizing the finite element method

A fatigue damage computational algorithm utilizing a multiaxial, isothermal, continuum based fatigue damage model for unidirectional metal matrix composites has been implemented into the commercial finite element code MARC using MARC user subroutines. Damage is introduced into the finite element solution through the concept of effective stress which fully couples the fatigue damage calculations with the finite element deformation solution. An axisymmetric stress analysis was performed on a circumferentially reinforced ring, wherein both the matrix cladding and the composite core were assumed to behave elastic-perfectly plastic. The composite core behavior was represented using Hill's anisotropic continuum based plasticity model, and similarly, the matrix cladding was represented by an isotropic plasticity model. Results are presented in the form of S-N curves and damage distribution plots.

Wilt, Thomas E.↗
NASA NTRS1994

Fracture mechanics validity limits

Fracture behavior is characteristics of a dramatic loss of strength compared to elastic deformation behavior. Fracture parameters have been developed and exhibit a range within which each is valid for predicting growth. Each is limited by the assumptions made in its development: all are defined within a specific context. For example, the stress intensity parameters, K, and the crack driving force, G, are derived using an assumption of linear elasticity. To use K or G, the zone of plasticity must be small as compared to the physical dimensions of the object being loaded. This insures an elastic response, and in this context, K and G will work well. Rice's J-integral has been used beyond the limits imposed on K and G. J requires an assumption of nonlinear elasticity, which is not characteristic of real material behavior, but is thought to be a reasonable approximation if unloading is kept to a minimum. As well, the constraint cannot change dramatically (typically, the crack extension is limited to ten-percent of the initial remaining ligament length). Rice, et al investigated the properties required of J-type parameters, J(sub x), and showed that the time rate, dJ(sub x)/dt, must not be a function of the crack extension rate, da/dt. Ernst devised the modified-J parameter, J(sub M), that meets this criterion. J(sub M) correlates fracture data to much higher crack growth than does J. Ultimately, a limit of the validity of J(sub M) is anticipated, and this has been estimated to be at a crack extension of about 40-percent of the initial remaining ligament length. None of the various parameters can be expected to describe fracture in an environment of gross plasticity, in which case the process is better described by deformation parameters, e.g., stress and strain. In the current study, various schemes to identify the onset of the plasticity-dominated behavior, i.e., the end of fracture mechanics validity, are presented. Each validity limit parameter is developed in detail, and then data is presented and the various schemes for establishing a limit of the validity are compared. The selected limiting parameter is applied to a set of fracture data showing the improvement of correlation gained.

Lambert, Dennis M.↗
NASA NTRS1994

Chemical recycling of scrap composites

There are no well-developed technologies for recycling composite materials other than grinding to produce fillers. New approaches are needed to reclaim these valuable resources. Chemical or tertiary recycling, conversion of polymers into low molecular weight hydrocarbons for reuse as chemicals or fuels, is emerging as the most practical means for obtaining value from waste plastics and composites. Adherent Technologies is exploring a low-temperature catalytic process for recycling plastics and composites. Laboratory results show that all types of plastics, thermosets as well as thermoplastics, can be converted in high yields to valuable hydrocarbon products. This novel catalytic process runs at 200 C, conversion times are rapid, the process is closed and, thus, nonpolluting, and no highly toxic gas or liquid products have been observed so no negative environmental impact will result from its implementation. Tests on reclamation of composite materials show that epoxy, imide, and engineering thermoplastic matrices can be converted to low molecular weight hydrocarbons leaving behind the reinforcing fibers for reuse as composite reinforcements in secondary, lower-performance applications. Chemical recycling is also a means to dispose of sensitive or classified organic materials without incineration and provides a means to eliminate or reduce mixed hazardous wastes containing organic materials.

Allred, Ronald E.↗
NASA NTRS1995

Analysis of LDEF experiment AO187-2 chemical and isotopic measurements of micrometeoroids by secondary ion mass spectrometry

#Experiment AO187-2, that was flown on board the Long Duration Exposure Facility(LDEF), was designed to measure the chemical and isotopic compositions of interplanetary dust impinging on the spacecraft from outer space. Information on the nature and composition of orbital debris was also anticipated. The spacecraft maintained a constant orientation with respect to its velocity vector thereby defining leading and trailing edges that faced respectively into and away from the direction of motion. Arrays of individual capture cells each 80.8 sq cm in size and totaling 237 in number were exposed on both the leading and trailing edges of LDEF. Each cell consisted of a pure Ge target surface slightly separated from a thin (2.5 micrometers) metallized plastic 'entrance foil.' The basic concept was that incoming projectiles would penetrate the foil, strike the Ge target plate at high velocity producing a vapor-liquid cloud that would re-deposit material on the underside of the plastic foil. This material would then be analyzed using the sensitive surface analysis technique of Secondary Ion Mass Spectrometry (SIMS). In practice, most of the plastic entrance foils failed during the extended period of orbital exposure probably due to a combination of UV embrittlement, large densities of impact events and (for the leading edge) the effects of atomic oxygen erosion in orbit. However the foils failed gradually and most remained in place on the capture cells for a significant fraction of the duration of the flight . Because most of the impactors were small (less than 10 micrometers) they were heated and dispersed in traversing the entrance foils producing clouds of molten droplets and vapor that produced easily identifiable 'extended impacts' on the Ge target plates. Fortunately, it proved possible to make ion probe measurements of projectile compositions from material deposited on the Ge in the extended impact structures.

Zinner, Ernst↗
NASA NTRS1995

Neutrons, gamma rays, and beta particles interactions with IIaO films flown on Astro I and Astro II and comparison with IIaO flown on the get-away-special STS-7

The current requirements for the Laboratory for Astronomy and Solar Physics, sends rocket satellites and in the near future will involve flights in the shuttle to the upper reaches of the Earth's atmosphere where they will be subjected to the atomic particles and electromagnetic radiation produced by the Sun and other cosmic radiation. It is therefore appropriate to examine the effect of neutrons, gamma rays, beta particles, and X-rays on the film currently being used by the Laboratory for current and future research requirements. It is also hoped by examining these particles in their effect that we will have simulated the space environment of the rockets, satellites, and shuttles. Several samples of the IIaO film were exposed to a neutron howitzer with a source energy of approximately 106 neutrons/steradians. We exposed several samples of the film to a 10 second blast of neutrons in both metal and plastic containers which exhibited higher density readings which indicated the possibility of some secondary nuclear interactions between neutrons and the aluminum container. The plastic container showed some variations at the higher densities. Exposure of the samples of IIaO film to a neutron beam of approximately 10 neutrons per steradians for eight minutes produces approximately a 13% difference in the density readings of the dark density grids. It is not noticeable that at the lighter density grid the neutrons have minimal effects, but on a whole the trend of the eight minute exposed IIaO film density grids at the darker end had a 7.1% difference than the control. Further analysis is anticipated by increasing the exposure time. Two sets of film were exposed to a beta source in a plastic container. The beta source was placed at the bottom so that the cone of rays striking the film would be conical for a period of seven days. It was observed in the films, designated 4a and 4b, a dramatic increase in the grid densities had occurred. The attenuation of beta particles due to the presence of air were observed. The darker density grids, whose positions were the furthest from the beta source, displayed minimal fluctuations as compared with the control. It is suspected that the orientation of the film in the cansister with the beta source is the key factor responsible for the dramatic increases of the lighter density grids. Emulsions 3a and 3b exposed for a period of six days with the grid orientation reserved produced substantial differences in the darker grids as shown in the graphs. There is a great deal of fluctuations in this sample between the beta exposed density grids and the control density grids. The lighter density grids whose orientations were reversed displays minimal fluctuations due to the presence of this beta source and the attenuation that is taking place.

Hammond, Ernest C., Jr.↗
NASA NTRS1998

Cell Kinetic and Histomorphometric Analysis of Microgravitational Osteopenia: PARE.03B

Previous methods of identifying cells undergoing DNA synthesis (S-phase) utilized H-3 thymidine (3HT) autoradiography. 5-Bromo-2'-deoxyuridine (BrdU) immunohistochemistry is a nonradioactive alternative method. This experiment compared the two methods using the nuclear volume model for osteoblast histogenesis in two different embedding media. Twenty Sprague-Dawley rats were used, with half receiving 3HT (1 micro Ci/g) and the other half BrdU (50 microgram/g). Condyies were embedded (one side in paraffin, the other in plastic) and S-phase nuclei were identified using either autoradiography or immunohistochemistry. The fractional distribution of preosteoblast cell types and the percentage of labeled cells (within each cell fraction and label index) were calculated and expressed as mean q standard error. Chi-Square analysis showed only a minor difference in the fractional distribution of cell types. However, there were significant differences (p less than 0.05) by ANOVA, in the nuclear labeling of specific cell types. With the exception of the less-differentiated A+A'cells, more BrdU label was consistently detected in paraffin than in plastic-embedded sections. In general, more nuclei were labeled with 3H-thymidine than with BrdU in both types of embedding media. Labeling index data (labeled cells/total cells sampled x 100) indicated that BrdU in paraffin, but not plastic gave the same results as 3HT in either embedding method. Thus, we conclude that the two labeling methods do not yield the same results for the nuclear volume model and that embedding media is an important factor whenusing BrdU. As a result of this work, 3HT was chosen for used in the PARE.03 flight experiments.

Roberts, W. Eugene↗
NASA NTRS1998

Cell Kinetic and Histomorphometric Analysis of Microgravitational Osteopenia: PARE.03B

Previous methods of identifying cells undergoing DNA synthesis (S-phase) utilized 3H-thymidine (3HT) autoradiography. 5-Bromo-2'-deoxyuridine (BrdU) immunohistochemistry is a nonradioactive alternative method. This experiment compared the two methods using the nuclear volume model for osteoblast histogenesis in two different embedding media. Twenty Sprague-Dawley rats were used, with half receiving 3HT (1 micro-Ci/g) and the other half BrdU (50 micro-g/g). Condyles were embedded (one side in paraffin, the other in plastic) and S-phase nuclei were identified using either autoradiography or immunohistochemistry. The fractional distribution of preosteoblast cell types and the percentage of labeled cells (within each cell fraction and label index) were calculated and expressed as mean +/- standard error. Chi-Square analysis showed only a minor difference in the fractional distribution of cell types. However, there were,significant differences (p less than 0.05) by ANOVA, in the nuclear labeling of specific cell types. With the exception of the less-differentiated A+A' cells, more BrdU label was consistently detected in paraffin than in plastic-embedded sections. In general, more nuclei were labeled with 3H-thymidine than with BrdU in both types of embedding media (Fig 2.). Labeling index data (labeled cells/total cells sampled x 100) indicated that BrdU in paraffin, but not plastic gave the same results as 3HT in either embedding method. Thus, we conclude that the two labeling methods do not yield the same results.

Roberts, W. Eugene↗
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.↗