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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Rotating Liner Engine: Improving Efficiency of Heavy Duty Diesels by Significant Friction Reduction, and Extending the Life of Heavy Duty Engines.

This report describes the work on converting a 4 cylinder Cummins ISB engine into a single cylinder Rotating Liner Engine functioning prototype that can be used to measure the friction benefits of rotating the cylinder liner in a high pressure compression ignition engine. A similar baseline engine was also prepared, and preliminary testing was done. Even though the fabrication of the single cylinder prototype was behind schedule due to machine shop delays, the fundamental soundness of the design elements are proven, and the engine has successfully functioned. However, the testing approach of the two engines, as envisioned by the original proposal, proved impossible due to torsional vibration resonance caused by the single active piston. A new approach for proper testing has been proposed,

Rotating Liner Engine, Engine Friction, Friction R↗
DOE OSTI2021

Strength in Rotary Friction Welding of Five Dissimilar Nickel-Based Superalloys

Advanced manufacturing processes improve the cost and quality of goods. Rotary friction welding is a fast, energy-efficient, and reliable joining process for metals, but new applications are hindered by large development costs for each new alloy. Each alloy set has different welding characteristics; therefore, lessons learned from a single alloy are not always broadly applicable. To establish knowledge that is applicable across multiple alloys, a family of different superalloys were welded to discover process trends that were applicable beyond a single alloy set. In this study, weld symmetry did not correlate to weld strength across alloy systems. Some alloys’ strongest welds occurred at maximum symmetry, whereas high asymmetry was associated with different alloys’ maximum strength. High feed rates, high welding forces, low energy, and low temperatures all resulted in high-strength welds across all alloy and geometry combinations. Tensile strengths greater than 95% of base-metal strength were recorded for most alloy systems.

36 MATERIALS SCIENCE↗
NASA NTRS1952

Friction and Wear

From the practical point of view, this analysis shows that each problem of friction or wear requires its particular solution. There is no universal solution; one or other of the factors predominates and defines the choice of the solution. In certain cases, copper alloys of great thermal conductivity are preferred; in others, plastics abundantly supplied with water. Sometimes, soft antifriction metals are desirable to distribute the load; at other times, hard metals with high resistance to abrasion or heat.

HEAT TRANSMISSION - FLUIDS AND SOLIDS↗
DOE OSTI2017

Sensitivity of Induced Seismic Sequences to Rate-and-State Frictional Processes

It is well established that subsurface injection of fluids increases pore fluid pressures that may lead to shear failure along a preexisting fault surface. Concern among oil and gas, geothermal, and carbon storage operators has risen dramatically over the past decade due to the increase in the number and magnitude of induced earthquakes. Efforts to mitigate the risk associated with injection-induced earthquakes include modeling of the interaction between fluids and earthquake faults. Here we investigate this relationship with simulations that couple a geomechanical reservoir model and RSQSim, a physics-based earthquake simulator. RSQSim employs rate- and state-dependent friction (RSF) that enables the investigation of the time-dependent nature of earthquake sequences. We explore the effect of two RSF parameters and normal stress on the spatiotemporal characteristics of injection-induced seismicity. We perform >200 simulations to systematically investigate the effect of these model components on the evolution of induced seismicity sequences and compare the spatiotemporal characteristics of our synthetic catalogs to observations of induced earthquakes. We find that the RSF parameters control the ability of seismicity to migrate away from the injection well, the total number and maximum magnitude of induced events. Additionally, the RSF parameters control the occurrence/absence of premonitory events. Finally, we find that earthquake stress drops can be modulated by the normal stress and/or the RSF parameters. Insight gained from this study can aid in further development of models that address best practice protocols for injection operations, site-specific models of injection-induced earthquakes, and probabilistic hazard and risk assessments.

58 GEOSCIENCES↗
DOE OSTI2020

Anisotropic Optical and Frictional Properties of Langmuir–Blodgett Film Consisting of Uniaxially-Aligned Rod-Shaped Cellulose Nanocrystals

Langmuir–Blodgett (LB) film deposition gives an opportunity to control the packing density and orientation of anisotropic nanoparticles at a monolayer level, allowing accurate characterization of their anisotropic material properties. Additionally, the uniaxial deposition of rod-shaped cellulose nanocrystals (CNCs) over a macroscopically large area is achieved by aligning the long axis of CNCs on the LB trough with the direction of the maximum drag force within the meniscus during the vertical pulling of the substrate from the LB trough. On the uniaxially-aligned LB films, anisotropic linear and non-linear optical properties of CNCs are obtained using Mueller matrix spectroscopy and sum frequency generation spectroscopy, respectively, and explained with time-dependent density functional theory calculations. Also, the frictional anisotropy of the LB film is measured using atomic force microscopy and explained theoretically. The findings of this study will be valuable for preparation of anisotropic nanoparticle thin films with uniform arrangements and utilization of their anisotropic material properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A Comparative Study of Two BAM Designs for Friction Sensitivity Testing of Explosives

A new commercial design of BAM friction tester that utilizes a programmable servo motor was tested in comparison to the traditional cam-driven model. Displacement and velocity profiles were analyzed for both designs; significant differences were found between the two designs, most notable of which is that the traditional cam-driven unit has plate velocities that can be 50–75 % greater than those seen on the servo-driven model. Five energetic materials were also tested on each machine, including PETN, RDX, HMX, CL-20, and HNAB. Finally, results from the servo-driven model generally showed slightly less sensitivity when compared to the cam driven model, though the magnitude of the difference is not significant enough to require modification of safe handling procedures for the materials tested.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2022

Microstructural modification of a high-pressure die-cast A380 alloy through friction stir processing and its effect on mechanical properties

Aluminum alloy A380 is one of the major high-pressure die-cast (HPDC) alloys fabricated in the die casting sector. However, microstructural features such as shrinkage and gas porosity, entrapped oxide inclusions, change in the morphology of eutectic Si particles as a function of casting location, and the presence of multiple second phase particulates, especially Fe-bearing phases in HPDC A380 alloy results in limited ductility, thus, affecting its structural application. However, through proper modification of the as-cast microstructure, it is possible to improve the mechanical performance of alloy A380. In this study, we report the effect of friction stir processing (FSP), a well-known severe plastic deformation (SPD) and thermomechanical processing tool for selective microstructural modification, on A380. FSP effectively refines the as-cast microstructure and breaks down the coarse Si particles, creating a homogenized distribution of equiaxed Si particles in the aluminum matrix. Additionally, FSP eliminates porosity that acts as crack initiation sites, leading to improved mechanical strength and ductility.

Friction stir processing, Aluminum alloys, Mechani↗
DOE OSTI2023

Embedded anchoring of multi-material assemblies by friction riveting process

In this paper, we report on work that focused on extending the capability and broaden the applicability of the friction-riveting process for joining stacks composed of a wide range of multi-layer polymer-to-metals and similar and dissimilar metals. We first present direct experimental evidence of our use of this process to join aluminum-to-steel dissimilar metals with steel rivets. We have demonstrated for the first time the use of magnesium as a rivet material for joining carbon fiber reinforced polymer (CFRP) stacks, aluminum as a rivet material to laminate magnesium to CFRP, and aluminum-to-aluminum similar metal joining and aluminum-to-steel dissimilar metal joining with steel rivets. Our work sheds light on detailed process parameter optimization and the corresponding process response behavior, thus advancing our understanding of this complex joining method for a wide range of material combinations.

Friction-riveting, magnesium rivet, carbon fiber r↗
DOE OSTI2023

THE ROLE OF FRACTURE PROPERTIES ON LAP JOINT STRENGTH OF FRICTION STIR WELDED AA7055-T6 SHEETS

Friction stir lap welded (FSLW) joints have weight-saving potential in aluminum-intensive automotive assembly. However, FSLW also modifies the material microstructure close to the joint. Optimizing the FSLW process requires understanding the relationship between the strength and the joint's microstructure. In previous studies, efforts have been dedicated to determining the effects of local softening, the shape of the oxide line, and porosity. However, the impact of changes to the fracture properties on the joint's strength has not been studied. In this work, strength testing, and simulations, aided by material characterization, were used to determine the role of fracture properties on the shear strength of a 3-sheet (aluminum alloys 7055-7055-6022) lap joint. Characterization involved testing for fracture properties in the weld region. This data was then implemented into finite element simulations. As a result, the joint strength was predicted with a deviation of less than 6% from the experimental value. Comparison with strength prediction using only the base metal properties indicates that fracture property in the nugget region determines the strength of AA7055 FSLW.

Finite element analysis, Friction stir welding, ma↗
DOE OSTI2023

Enhanced Tensile and Tear Toughness Properties of Thin-Wall Vacuum-Assisted High-Pressure Die-Cast Aural-5 Alloy by Friction Stir Processing

Steadily rising demand for glider weight reduction has driven the development of vacuum-assisted high-pressure die-cast (HPDC) Al-alloys for automotive structural components. Aural-5 is a strontium-modified HPDC alloy utilizing manganese (Mn) to reduce die soldering, eliminating detrimental needle-shaped Fe-bearing ß-phase intermetallic and improving ductility. HPDC Aural-5 contains shrinkage porosity, dendrites with Al-Si eutectic colonies, externally solidified crystals (ESCs), shear-band structure, and large second-phase particulates. Porosity, ESCs and large second-phase particles work as crack initiation sites, negatively impacting tensile properties. In this study, friction stir processing (FSP) is employed for microstructural modification of a thin-walled HPDC Aural-5 by eliminating porosity and breaking down dendrites, second-phase particles, eutectic colonies, ESCs and shear-band structures to create wrought microstructure with homogenized particle distribution. Mechanical property characterization indicates ~30% and ~35% enhancement in yield strength and ductility and associated marked effects on ~69% improvement in tear toughness according to the ASTM B871 test.

Friction stir processing, Aural-5, Strength, Tear ↗
DOE OSTI2024

Meshfree Process Modeling and Experimental Validation of Friction Riveting of Aluminum 5052 to Aluminum 6061

Friction riveting (Fric-riveting) is an innovative, fast, and energy-efficient process for spot-joining metal-metal structures. Although fric-riveting has been studied experimentally in recent years, its process modeling is rarely found in the literature primarily because of the associated large material deformation, extreme thermomechanical conditions, and complex contact conditions. In this work, a mesh-free smoothed particle hydrodynamics (SPH) framework that can well handle the abovementioned numerical challenges is used to simulate the fric-riveting of AA5052 to AA6061. Predicted material morphology, multi-point temperatures, and plunge force are thoroughly validated by experimental observations. The material severe plastic deformation zone in the vicinity of the riveting zone is further predicted by the SPH model, which indicates the material mixing and potential grain refinement zone. Based on the validated model, process parameters can be optimized which yields better performance over the baseline case.

Friction riveting (fric-riveting), Smoothed partic↗