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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 1,045 records · Page 58
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Ta, Ti and Hf effects on Nb 3 Sn high-field performance: temperature-dependent dopant occupancy and failure of Kramer extrapolation

The increasing demand for improving the high-field (16-22 T) performance of Nb 3 Sn conductors requires a better understanding of the properties of modern wires much closer to irreversibility field, H Irr . In this study we investigated the impact of Ta, Ti and Hf doping on the high-field pinning properties, the upper critical field, H c2 , and H Irr . We found that the pinning force curves of commercial Ti and Ta doped wires at different temperatures do not scale and that the Kramer extrapolation, typically used by magnet designers to estimate high-field critical current density and magnet operational margins from lower field data, is not reliable and significantly overestimates the actual H Irr . In contrast, new laboratory scale conductors made with Nb-Ta-Hf alloy have improved high-field J c performance and, despite contributions by both grain boundary and point defect pinning mechanisms, have more predictable high-field behavior. Using Extended X-ray Absorption Fine Structure spectroscopy, EXAFS, we found that for the commercial Ta and Ti doped conductors, the Ta site occupancy in the A15 structure gradually changes with the heat treatment temperature whereas Ti is always located on the Nb site with clear consequences for H c2 . Finally, this work reveals the still limited understanding of what determines H c2 , H Irr and the high-field J c performance of Nb 3 Sn and the complexity of optimizing these conductors so that they can reach their full potential for high-field applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Significant reduction in the low-field magnetization of Nb 3 Sn superconducting strands using the internal oxidation APC approach

Nb 3 Sn superconductors are promising for building accelerator magnets for future energy-frontier circular colliders. A critical factor for this application is the low-field persistent-current magnetization because it leads to several critical issues: e.g. low-field instability (including flux jumps), hysteresis loss, and field errors in magnet bores. Suppression of low-field magnetization requires reduction of low-field critical current density (J c ) or effective subelement size (d eff ). However, reduction of deff of state-of-the-art Nb 3 Sn conductors—the restacked-rod-process (RRP ® ) type—below 40–50 μm without a pronounced decrease in high-field J c is difficult. On the other hand, the internal oxidation method which forms artificial pinning centers (APC) in Nb 3 Sn offers an alternative approach to reducing the low-field magnetization. Compared with a conventional Nb 3 Sn conductor whose flux pinning force versus field (F p –B) curve peaks at ~20% of its irreversibility field (B irr ), the F p –B curve peaks of APC conductors shift to higher fields due to the point pinning effect, leading to flattening of the J c –B curves. The goal of this paper is to quantitatively study how much the APC approach can reduce the low-field magnetization. Here we measured the J c –B curves of an RRP ® conductor and two APC conductors (reacted at 700 °C) from zero field to B irr using a high-field vibrating sample magnetometer. Here the results showed that the APC conductors have higher non-Cu J c at high fields (e.g. 32%–41% higher at 16 T) and simultaneously lower non-Cu Jc at low fields (e.g. 28%–34% lower at 1 T) compared with the RRP ® . This effect is due to a competition between their Nb3Sn layer fraction ratios and layer F p ratios. Suppose they reach the same 16 T non-Cu J c , then the 1 T non-Cu J c and magnetization of the APC conductors are only half or even less compared with the RRP ® conductor.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Vortex phase diagram of the kagome superconductor CsV 3 ⁢Sb 5

The screening response of the kagome superconductor CsV 3 ⁢Sb 5 was obtained from high-resolution ac mutual inductance measurements. At zero applied magnetic field and low temperatures, we observe no evidence for gapless quasiparticles, while near T c we find evidence for enhanced fluctuations. A rich vortex state appears above H c⁢1 ≈30 Oe, exhibiting successive emergence of vortex phases. For a fixed magnetic field, lowering the temperature below T c⁡ (H) leads to a wide range of vortex liquid state in a landscape of weak pinning potential, which gives rise to an irreversibility line. Further lowering the temperature, we identify the vortex melting line followed by the peak effect manifested in enhanced vortex pinning strength and critical current. Finally, we suggest that such an unusual behavior, where the peak effect region is fully contained within the vortex lattice state below the irreversibility line, is a consequence of the strong anisotropy and weak bulk pinning in CsV 3 ⁢Sb 5 .

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2013

Pulsed Magnetic Welding for Advanced Core and Cladding Steel

To investigate a solid-state joining method, pulsed magnetic welding (PMW), for welding the advanced core and cladding steels to be used in Generation IV systems, with a specific application for fuel pin end-plug welding. As another alternative solid state welding technique, pulsed magnetic welding (PMW) has not been extensively explored on the advanced steels. The resultant weld can be free from microstructure defects (pores, non-metallic inclusions, segregation of alloying elements). More specifically, the following objectives are to be achieved: 1. To design a suitable welding apparatus fixture, and optimize welding parameters for repeatable and acceptable joining of the fuel pin end-plug. The welding will be evaluated using tensile tests for lap joint weldments and helium leak tests for the fuel pin end-plug; 2 Investigate the microstructural and mechanical properties changes in PMW weldments of proposed advanced core and cladding alloys; 3. Simulate the irradiation effects on the PWM weldments using ion irradiation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Regulatory Technology Development Plan - Sodium Fast Reactor. Mechanistic Source Term - Metal Fuel Radionuclide Release

The development of an accurate and defensible mechanistic source term will be vital for the future licensing efforts of metal fuel, pool-type sodium fast reactors. To assist in the creation of a comprehensive mechanistic source term, the current effort sought to estimate the release fraction of radionuclides from metal fuel pins to the primary sodium coolant during fuel pin failures at a variety of temperature conditions. These release estimates were based on the findings of an extensive literature search, which reviewed past experimentation and reactor fuel damage accidents. Data sources for each radionuclide of interest were reviewed to establish release fractions, along with possible release dependencies, and the corresponding uncertainty levels. Although the current knowledge base is substantial, and radionuclide release fractions were established for the elements deemed important for the determination of offsite consequences following a reactor accident, gaps were found pertaining to several radionuclides. First, there is uncertainty regarding the transport behavior of several radionuclides (iodine, barium, strontium, tellurium, and europium) during metal fuel irradiation to high burnup levels. The migration of these radionuclides within the fuel matrix and bond sodium region can greatly affect their release during pin failure incidents. Post-irradiation examination of existing high burnup metal fuel can likely resolve this knowledge gap. Second, data regarding the radionuclide release from molten high burnup metal fuel in sodium is sparse, which makes the assessment of radionuclide release from fuel melting accidents at high fuel burnup levels difficult. This gap could be addressed through fuel melting experimentation with samples from the existing high burnup metal fuel inventory.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Glovebox Advanced Casting System Casting Optimization

Casting optimization in the GACS included three broad areas; casting of U-10Zr pins, incorporation of an integral FCCI barrier, and development of a permanent crucible coating. U-10Zr casting was improved over last year’s results by modifying the crucible design to minimize contact with the colder mold. Through these modifications casting of a three pin batch was successful. Incorporation of an integral FCCI barrier also was optimized through furnace chamber pressure changes during the casting cycle to reduce gas pressures in the mold cavities which led to three full length pins being cast which incorporated FCCI barriers of three different thicknesses. Permanent crucible coatings were tested against a base case; 1500°C for 10 minutes in a U-20Pu-10Zr molten alloy. None of the candidate coating materials showed evidence of failure upon initial visual examination. In all areas of work a large amount of characterization will be needed to fully determine the effects of the optimization activities. The characterization activities and future work will occur next year.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Submission of FeCrAl Feedstock for Support of AFC ATR-2 Irradiations

The Advanced Test Reactor (ATR) is currently being used to test accident tolerant fuel (ATF) forms destined for commercial nuclear power plant deployment. One irradiation program using the ATR for ATF concepts, Accident Tolerant Fuel-2 (ATF-2), is a water loop irradiation test using miniaturized fuel pins as test articles. This complicated testing configuration requires a series of pre-test experiments and verification including a flowing loop autoclave test and a sensor qualification test (SQT) prior to full test train deployment within the ATR. In support of the ATF-2 irradiation program, Oak Ridge National Laboratory (ORNL) has supplied two different Generation II FeCrAl alloys in rod stock form to Idaho National Laboratory (INL). These rods will be machined into dummy pins for deployment in the autoclave test and SQT. Post-test analysis of the dummy pins will provide initial insight into the performance of Generation II FeCrAl alloys in the ATF-2 irradiation experiment as well as within a commercial nuclear reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Discrete ordinate quadrature selection for reactor-based Eigenvalue problems

In this paper we analyze the effect of various quadrature sets on the eigenvalues of several reactor-based problems, including a two-dimensional (2D) fuel pin, a 2D lattice of fuel pins, and a three-dimensional (3D) reactor core problem. While many quadrature sets have been applied to neutral particle discrete ordinate transport calculations, the Level Symmetric (LS) and the Gauss-Chebyshev product (GC) sets are the most widely used in production-level reactor simulations. Other quadrature sets, such as Quadruple Range (QR) sets, have been shown to be more accurate in shielding applications. In this paper, we compare the LS, GC, QR, and the recently developed linear-discontinuous finite element (LDFE) sets, as well as give a brief overview of other proposed quadrature sets. We show that, for a given number of angles, the QR sets are more accurate than the LS and GC in all types of reactor problems analyzed (2D and 3D). We also show that the LDFE sets are more accurate than the LS and GC sets for these problems. We conclude that, for problems where tens to hundreds of quadrature points (directions) per octant are appropriate, QR sets should regularly be used because they have similar integration properties as the LS and GC sets, have no noticeable impact on the speed of convergence of the solution when compared with other quadrature sets, and yield more accurate results. We note that, for very high-order scattering problems, the QR sets exactly integrate fewer angular flux moments over the unit sphere than the GC sets. The effects of those inexact integrations have yet to be analyzed. We also note that the LDFE sets only exactly integrate the zeroth and first angular flux moments. Pin power comparisons and analyses are not included in this paper and are left for future work. (authors)

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2013

Increasing the power density when using inert matrix fuels to reduce production of transuranics

Reducing the production of transuranics is a goal of most advanced nuclear fuel cycles. One way to do this is to recycle the transuranics into the same reactors that are currently producing them using an inert matrix fuel. In previous work we have modeled such a reactor where 72%, of the core is comprised of standard enriched uranium fuel pins, with the remaining 28% fuel made from Yttria stabilized zirconium, in which transuranics are loaded. A key feature of this core is that all of the transuranics produced by the uranium fuel assemblies are later burned in inert matrix fuel assemblies. It has been shown that this system can achieve reductions in transuranic waste of more than 86%. The disadvantage of such a system is that the core power rating must be significantly lower than a standard pressurized water reactor. One reason for the lower power is that high burnup of the uranium fuel precludes a critical level of reactivity at the end of the campaign. Increasing the uranium enrichment and changing the pin pitch are two ways to increase burnup while maintaining criticality. In this paper we use MCNPX and a linear reactivity model to quantify the effect of these two parameters on the end of campaign reactivity. Importantly, we show that in the region of our proposed reactor, enrichment increases core reactivity by 0.02 per percent uranium 235 and pin pitch increases reactivity by 0.02 per mm. Reactivity is lost at a rate of 0.005 per MWd/kgIHM uranium burnup. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Full core LOCA analysis for BWR/6 - Methodology and first results

As part of collaboration between the Paul Scherrer Institute (PSI) and the Swiss regulator ENSI, a study aimed at core-wide estimates of the fuel rod behaviour during large-break loss-of-coolant-accidents (LB-LOCA) in BWR/6 plants was recently conducted on the basis of a Swiss reactor. To perform such full core LOCA analysis, a methodology consisting of a multi-physics sequence of interfaced best-estimate models and codes was established: CASMO-4E/SIMULATE-3 (C4/S3) for the core modelling, TRACE for the plant system analysis and FALCON for the fuel thermomechanical calculations during base irradiation (BI) as well as for the transient analyses (TA). As starting point, reference C4/S3 models validated for all operated cycles of the given plant were used to select as situation target, a recent cycle representative of modern BWR core loadings and fuel assembly designs. Based on the selected C4/S3 cycle model, PSI in-house computational modules were developed or updated in order to set up the TRACE full core model with regards to assembly geometries, fuel rods thermophysical properties and initial 3-D power distributions. Also, an interface to FALCON BI models was established for the transfer of the irradiation history, including primarily linear heat generation rates (LHGR), for an equivalent fuel pin. For each assembly, the power of the equivalent pin is defined with the maximum power of all pins at each axial position. However, in order to reduce the computational time of the fuel performance analyses, the whole core was subdivided into groups of assemblies, each represented by the most powerful assembly within the group. On this basis, the FALCON BI analyses were conducted with coupling to the PSI advanced model for gas release and swelling (GRWS-A) and an interface was developed to transfer the calculated fuel rod characteristics at end of irradiation to initialize the core fuel rods heat structures in the TRACE model. Subsequently, double-ended recirculation line rupture scenarios at hot-full-power (HFP) conditions were investigated with TRACE in order to determine a conservative transient case as function of cycle burnup, single failure criterion and availability of safety systems. For the most conservative case of this study, an interface was set-up to transfer the TRACE results as boundary conditions to the FALCON TA models, including thus primarily time and axial distributions of the clad outer temperatures. As final step, the FALCON TA were conducted for the representative assemblies in order to infer core-wide estimates of the fuel rod behaviour with specific focus on equivalent cladding reacted levels, hoop strains as well as margins to failure criteria. The objective of this paper is to present this methodology along with the obtained first results. Regarding the latter, it is found that principally, even for the most conservative LOCA scenario of this study, the clad temperature excursion remains mild enough at all core locations such that no significant rod ballooning and no cladding failure is predicted, something in line with corresponding analyses conducted earlier for BWR/4 plants. (authors)

42 ENGINEERING↗
DOE OSTI2016

Nitride Fuel Potential for Power Uprates

This work presents the methodology and current results for design analysis of grid supported pressurized water reactor cores using uranium nitride (UN) fuel in square arrays. Uranium nitride has a higher theoretical density and higher thermal conductivity than uranium oxide, allowing for lower fuel temperatures, longer cycle length and higher power densities with similar enrichment. In order to avoid the UN and high temperature water reaction, silicon carbide cladding has been proposed in place of Zircaloy cladding. The analysis aims at finding the maximum thermal power over a range of bundle geometries (rod diameter and pitch). The same methodology is applied to the design of UO{sub 2} oxide fueled cores to provide a fair comparison of the achievable power rating between the two fuel types. Steady-state limits are considered, including fuel bundle pressure drop, minimum departure from nucleate boiling ratio (MDNBR), fuel temperature, fuel rod vibrations and pin fretting and sliding wear. Transients such as loss of flow and overpower accident will be considered. A steady state analysis was undertaken to determine the maximum achievable power that can be sustained by square array fuel assemblies loaded with nitride and oxide fuels with same or better safety performances as the reference design. Steady-state design limits were applied including MDNBR, fuel bundle pressure drop, fuel temperature, cumulative sliding and fretting wear. The major conclusions of this study are as follows: 1) It is possible to achieve significant power increase for UN and UO{sub 2} compared to the reference core power output of 3400 MWth with smaller but more numerous rods and higher pitch over diameter ratios. A power uprate of 25% can be reached according to the VIPRE-MATLAB interface for full core analysis with the same number of spacer grids, and 32% according to the new MATLAB script for single hot channel analysis, with five more spacer grids. For this latter core, a higher enrichment would be required. 2) The nitride fuel temperature constraint from dissociation doesn't influence steady state performances as other design constraints such as MDNBR and pressure loss are more restrictive. The oxide fuel temperature constraint from fission gas release is reached in part of the study domain, but not in the region that allows for possible uprates. 3) As a result, the thermal hydraulic performance of UN and UO{sub 2} are similar. Differences in possible power uprates will arise from fretting and sliding wear. Wear depends of the time spent by the fuel in the core, which depends on burnup and heavy metal inventory. UN being denser, it can allow for power uprates or increased cycle length. There is a trade off between power uprates and cycle length with regards to fuel pin wear. Reducing fuel pin wear by reducing cycle length can allow for higher thermal power. This affects the plants' economics as well. This work will be completed by a transient analysis using CASMO4E, SIMULATE3 and SIMULATE3k to model the neutronics of a nitride fueled core. The transient performances will be used to determine the maximum power uprates while performing as well or better during transients as the reference design. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Metal Fuel Implications on Severe Accident Scenarios

Superior steady-state irradiation performance of metal fuel has been demonstrated, and metal fuel has been the choice for recent sodium-cooled fast reactor designs, e.g. PRISM, SAFR, 4S, TWR, PGSFR, and so on. Metal fuel also has excellent transient capabilities. The metal fuel itself does not impose any restrictions on transient operations or load-following capabilities. Metal fuel has benign run beyond cladding breach (RBCB) performance characteristics. Because metal fuel is compatible with sodium, there is no reaction product and the fuel loss is practically zero. Metal fuel is expected to be very reliable. However, even if unforeseen fuel pin failure occurs, it will simply release gases and does not cause failure propagation to neighboring pins. The eutectic formation temperature between the fuel and the cladding has been considered a critical parameter for the metal fuel pin design. The onset of fuel-cladding eutectic formation starts in the 700-725 deg. C temperature range, depending on the fuel alloy and cladding types. However, at this onset temperature, not much interaction occurs. In fact, even at 100 deg. C above the eutectic temperature, the eutectic penetration into the cladding is minimal in one hour. Only at much higher temperatures, close to the fuel melting point itself, the eutectic penetration into cladding becomes rapid. Therefore, the eutectic formation is not a primary safety concern during transient overpower conditions. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Visualization of dynamic fiber-matrix interfacial shear debonding

To visualize the debonding event in real time for the study of dynamic crack initiation and propagation at the fiber–matrix interface, a modified tension Kolsky bar was integrated with a high-speed synchrotron X-ray phase-contrast imaging setup. In the gage section, the pull-out configuration was utilized to understand the behavior of interfacial debonding between SC-15 epoxy matrix and S-2 glass fiber, tungsten wire, steel wire, and carbon fiber composite Z-pin at pull-out velocities of 2.5 and 5.0 m s –1 . The load history and images of the debonding progression were simultaneously recorded. Both S-2 glass fiber and Z-pin experienced catastrophic interfacial debonding whereas tungsten and steel wire experienced both catastrophic debonding and stick–slip behavior. Even though S-2 glass fiber and Z-pin samples exhibited a slight increase and tungsten and steel wire samples exhibited a slight decrease in average peak force and average interfacial shear stress as the pull-out velocities were increased, no statistical difference was found for most properties when the velocity was increased. Furthermore, the debonding behavior for each fiber material is similar with increasing pull-out velocity. Thus, the debonding mechanism, peak force, and interfacial shear stress were rate insensitive as the pull-out velocity doubled from 2.5 to 5.0 m s –1 . In conclusion, scanning electron microscope imaging of recovered epoxy beads revealed a snap-back behavior around the meniscus region of the bead for S-2 glass, tungsten, and steel fiber materials at 5.0 m s –1 whereas those at 2.5 m s –1 exhibited no snap-back behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Studies on the Composite System of Bi-2212 Glass Ceramic and MgB{sub 2} Superconductors

The composites of glass ceramic Bi-2212 and MgB{sub 2} superconductors were prepared at ambient conditions. The transmission electron microscopy images of the composite samples illustrate the presence of glass ceramic inclusions in bulk MgB{sub 2}. Temperature-dependent magnetization of the composite samples shows two superconducting transitions: one at 80 K corresponding to the Bi-2212 phase and a second one at 39 K corresponding to the MgB{sub 2} phase, suggesting that the two superconducting phases are separated with clear boundaries. The critical current density (J{sub c}) and pinning force values are increased in composite systems by an order of magnitude compared to that of individual samples. The pinning mechanism in the composite sample is the same as in the matrix phase. Reduced field maxima (h{sub max}) are observed at 0.15 for composite samples. A low value of h{sub max} for composite samples indicates the random orientation of grain boundaries and repulsive pinning force in the composite samples.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Synthesis of CdS Nanoparticles by Hydrothermal Method and Their Effects on the Electrical Properties of Bi-based Superconductors

Cadmium sulfide (CdS) nanoparticles were synthesized by hydrothermal process and have been characterized by x-ray diffraction (XRD), transmission electron microscopy (TEM), and energy-dispersive x-ray spectroscopy (EDXS) system. The effect of added CdS nanoparticles on the superconducting properties and flux pinning capability in (Bi,Pb){sub 2}Sr{sub 2}Ca{sub 2}Cu{sub 3}O{sub y} system (denoted as (Bi,Pb)-2223) has been reported. Hydrothermal method is an effective route to synthesize CdS nanoparticles with good crystallinity and having average grain size of about 12 nm. Then, small amounts (0–0.4 wt%) of nanosized CdS particles were added to Bi-2233 samples using a solid-state reaction route. The transport critical current densities and the electrical resistivity ρ(T, H) were performed using the four-probe technique. The results show that samples sintered by small amount of CdS nanoparticles (≤ 0.3 wt%) exhibit the higher critical current densities and energy pinning in applied magnetic fields compared to free added sample. Consequently, the addition of CdS could introduce effective pinning centers which account for the improvement in superconducting properties in the Bi-2223 materials.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Structural, Electric and Magnetic Properties of Bi{sub 2}Sr{sub 2}Ag{sub 0.03}Ca{sub 1}Cu{sub 2}O{sub y} Ceramics Modified by Post-annealing

Polycrystalline Bi{sub 2}Sr{sub 2}Ag{sub 0.03}Ca{sub 1}Cu{sub 2}O{sub y} samples were fabricated using conventional solid-state reaction method. Then, post-annealing temperatures at 730, 780 and 830 {sup ∘}C were applied on samples while time was kept constant at 50 h. Both the x-ray diffraction (XRD) measurement and the scanning electron microscopy (SEM) showed that all samples have high amounts of Bi-2212 phase as the main phase, indicating that the selected starting composition is suitable to analyze the post-annealing effects on the flux pinning properties of Bi-2212 superconductors. In particular, flux pinning performance of Bi-2212 phase is observed from both the magnetic hysteresis loops and J{sub c} values calculated using Bean’s model. The highest J{sub c} value was obtained for sample which was not exposed to the post-annealing treatment. The results clearly show that post-annealing procedure in Bi{sub 2}Sr{sub 2}Ag{sub 0.03}Ca{sub 1}Cu{sub 2}O{sub y} system does not create artificial pinning centres, which lead to the improvements in J{sub c} at high magnetic fields.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Influence of FSW Repairing Process on the Microstructures and Mechanical Properties of Friction Stir-Welded 6082Al Alloy

When two 42-mm 6082Al plates were welded by friction stir welding (FSW), a discontinuously distributing groove defect is formed on the surface of the joint. Subsequently, the FSW repairing process was conducted at the defect location. The influence of the repairing process on the microstructures and mechanical properties of the joints were studied, and a description of the softening mechanism of the repaired joints is provided. The results show that TMAZ at the advance side is the weakest zone of the as-welded joints. The repairing process increases the heat input into the joints and thus promotes the coarsening and transformation of the precipitates in the joints, which further weakens the repaired joints. The average tensile strength of the joints repaired with a 24-mm pin is 205 MPa, which is 91% of that of the as-welded joint. The tensile strength generally increases when the size of the repaired pin decreases. The average tensile strength of the joints repaired with an 8-mm pin is 220 MPa, which is equivalent to the initial joints.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support

We present that friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For welds in lap configuration, an enhancement to this technology is made by introducing a short, hard insert, referred to as a cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanical computational model employing a coupled Eulerian-Lagrangian approach is developed to quantitatively capture the morphology of these interlocks during the FSW process. Simulations using this model are validated by experimental observations. In conclusion, the identified interface morphology coupled with the predicted temperature field from this process–structure model can be used to estimate the post-weld microstructure and joint strength.

36 MATERIALS SCIENCE↗