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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Laser Welding Dissimilar Reflective Alloys

This project, jointly sponsored by Rocketdyne and CSTAR, involves the development of laser joining of materials which have heretofore been impractical to bond. Of particular interest are joints between stainless steel and copper and also aluminum 6061 to aluminum 2219. CSTAR has a unique opportunity in this area since both the process and development and diagnostics are of interest to industry. Initial results using the pulse tailored laser welding technique developed in CLA for joining crack sensitive materials have proven promising for the aluminum joints based upon metallurgical and electronic microprobe analysis. A declaration of success requires additional mechanical testing. A CW technique has been applied to the stainless-copper joining with some preliminary success. These joints are of significant interest for aeronautics and rocket propulsion applications and the project is expected to continue.

Mccay, M. H.↗
NASA NTRS1996

Brazing Dissimilar Metals

Brazing effective technique for joining ordinary structural metals to brittle, low-thermal-expansion refractory metals. Specifically, brazing process established for joining copper or nickel flanges to ends of vacuum-plasma-sprayed tungsten tubes and for joining stainless-steel flanges to ends of tubes made of alloy of molybdenum with 40 percent of rhenium.

Krotz, Phillip D.↗
NASA NTRS1997

Determination of Stress Intensity Factor Distributions for "Interface" Cracks in Incompressible, Dissimilar Materials

The present study was undertaken in order to develop test methods and procedures for measuring the variation of the stress intensity factor through the thickness in bimaterial specimens containing cracks within and parallel to the bond line using the frozen stress photoelastic method. Since stress freezing materials are incompressible above critical temperature, and since thick plates are to be employed which tend to produce a state of plane strain near the crack tip, the interface near tip fracture equations reduce to the classic form for homogeneous materials. Moreover, zero thickness interfaces do not exist when materials are bonded together. It was decided early on that it would be important to insure a uniform straight and accurate crack tip region through the thickness of the body to reduce scatter in the SIF distribution through the thickness. It was also observed that rubberlike materials which were desired to be modeled exhibited significant tip blunting prior to crack extension and that some blunting of the tip would provide a more realistic model. It should be noted that, in normal stress freezing photoelastic work, it is considered good practice to avoid utilizing data near bond lines in photoelastic models due to the bond line stresses which inevitably develop when two parts are bonded together. Thus, the present study involves certain exploratory aspects in deviating from standard practice in stress freezing work. With the above ideas in mind, several different test methods were investigated and are described in the following sections and appendices. The geometry selected for the program was a thick, edge cracked specimen containing a bond line.

Smith, C. W.↗
NASA NTRS2010

Packing Optimization of an Intentionally Stratified Sorbent Bed Containing Dissimilar Media Types

The Fire Cartridge is a packed bed air filter with two different and separate layers of media designed to provide respiratory protection from combustion products after a fire event on the International Space Station (ISS). The first layer of media is a carbon monoxide catalyst made from gold nanoparticles dispersed on iron oxide. The second layer of media is universal carbon, commonly used in commercial respirator filters. Each layer must be optimally packed to effectively remove contaminants from the air. Optimal packing is achieved by vibratory agitations. However, if post-packing movement of the media within the cartridge occurs, mixing of the bed layers, air voids, and channeling could cause preferential air flow and allow contaminants to pass. Several iterations of prototype fire cartridges were developed to reduce post-packing movement of the media within each layer (settling), and to prevent mixing of the two media types. Both types of movement of the media contribute to decreased fire cartridge performance. Each iteration of the fire cartridge design was tested to demonstrate mechanical loads required to cause detrimental movement within the bed, and resulting level of functionality of the media beds after movement was detected. In order to optimally pack each layer, vertical, horizontal, and orbital agitations were tested and a final packed bulk density was calculated for each method. Packed bulk density must be calculated for each lot of catalyst to accommodate variations in particle size, shape, and density. In addition, a physical divider sheet between each type of media was added within the fire cartridge design to further inhibit intermixing of the bed layers.

Kidd, Jessica↗
NASA NTRS2011

Microhardness and Strain Field Characterization of Self-Reacting Friction Stir and Plug Welds of Dissimilar Aluminum Alloys

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. This work reports on material properties and strain patterns developed in a SR-FSW with a friction plug weld. Specifically, this study examines the behavior of a SR-FSW formed between an AA 2014-T6 plate on the advancing side and an AA 2219-T87 plate on the retreating side and a SR-FSW (AA 2014-T6 to AA 2219-T87) with a 2219-T87 plug weld. This study presents the results of a characterization of the micro-hardness, joint strength, and strain field characterization of SR-FSW and FPW joints tested at room temperature and cryogenic temperatures.

Horton, Karla Renee↗
NASA NTRS2011

Packing Optimization of Sorbent Bed Containing Dissimilar and Irregular Shaped Media

The Fire Cartridge is a packed bed air filter with two different and separate layers of media designed to provide respiratory protection from combustion products after a fire event on the International Space Station (ISS). The first layer of media is a carbon monoxide catalyst and the second layer of media is universal carbon. During development of Fire Cartridge prototypes, the two media beds were noticed to have shifted inside the cartridge. The movement of media within the cartridge can cause mixing of the bed layers, air voids, and channeling, which could cause preferential air flow and allow contaminants to pass through without removal. An optimally packed bed mitigates these risks and ensures effective removal of contaminants from the air. In order to optimally pack each layer, vertical, horizontal, and orbital agitations were investigated and a packed bulk density was calculated for each method. Packed bulk density must be calculated for each media type to accommodate variations in particle size, shape, and density. Additionally, the optimal vibration parameters must be re-evaluated for each batch of media due to variations in particle size distribution between batches. For this application it was determined that orbital vibrations achieve an optimal pack density and the two media layers can be packed by the same method. Another finding was media with a larger size distribution of particles achieve an optimal bed pack easier than media with a smaller size distribution of particles.

Holland, Nathan↗
NASA NTRS1983

Differences in the temporal variations of solar UV flux, 10.7-cm solar radio flux, sunspot number, and Ca-K plage data caused by solar rotation and active region evolution

Attention is given to two types of temporal variations in the solar UV spectral irradiance caused by solar rotation and active region evolution. It is noted that the first type of dissimilar temporal behavior occurs when concentrations of solar active regions evolve at solar longitudes nearly 180 deg apart. Both the UV observations and modeled UV fluxes based on Ca-K plage data then exhibit pronounced 13-day periodicity, whereas the 10.7-cm solar radio flux and sunspot number exhibit quite dissimilar temporal variations. This type of dissimilarity is related to the modeled UV flux and has a dependence on the solar central meridian distance that is narrower than that for the 10.7-cm radio flux or for sunspot numbers. A second case of marked dissimilarity is seen when major new solar active regions arise and dominate the full-disk fluxes for several rotations. It is found that the strongest peaks in 10.7 cm and sunspot numbers tend to occur on their first rotation, for example, during major dips in the total solar irradiance, whereas the Ca-K plages and UV enhancements peak on the next rotation and then decay more slowly on subsequent rotations.

Donnelly, R. F.↗
NASA NTRS2004

Global-Local Finite Element Analysis of Bonded Single-Lap Joints

Adhesively bonded lap joints involve dissimilar material junctions and sharp changes in geometry, possibly leading to premature failure. Although the finite element method is well suited to model the bonded lap joints, traditional finite elements are incapable of correctly resolving the stress state at junctions of dissimilar materials because of the unbounded nature of the stresses. In order to facilitate the use of bonded lap joints in future structures, this study presents a finite element technique utilizing a global (special) element coupled with traditional elements. The global element includes the singular behavior at the junction of dissimilar materials with or without traction-free surfaces.

Kilic, Bahattin↗
NASA NTRSDate not supplied

Micro-grid for Future Planetary Surface Needs

Under the current Artemis Program, the National Aeronautics and Space Administration (NASA) will send its next set of astronauts (first woman and next man) to the Moon by 2024 and establish a sustainable presence on the lunar surface by 2028. The challenge of creating a sustained lunar surface presence is significantly different than previous efforts. Lunar surface operations will require access to continuous and highly reliable power to support mission needs, such as to support ISRU operations. Adding to this challenge, the lunar surface operations are not going to be established over a single effort, rather the system and operations will evolve and grow over time (years). The first initial loads that arrive on the lunar surface will be integrated to their own dedicated power sources. As the lunar surface operations grow, so will the demand for power and at some point these individual loads will require more power than can be generated with any single power device. This power demand drives the need for inter-connecting the loads and power devices to share power between them, resulting in a micro-grid. One of the advantages of developing a lunar surface micro-grid is that allows lunar surface operations to resemble electrical utility operations on Earth; it allows power to be generated where it is convenient and allows power to be consumed where it is convenient, rather than negotiating between generation and consumption. The micro-grid concept also provides another benefit of affording the ability to increase overall system reliability by integrating dissimilar power generation and energy storage devices together, for example modifying the power generation strategy to include both solar arrays and nuclear. Creating a lunar surface micro-grid has its advantages, however there are significant challenges associated with an evolvable micro-grid concept. The challenges include how to efficiently transmit large amounts of power (10kW+) long distances (1kW+), how to effectively integrate dissimilar power generation and energy storage devices to maximize power consumption and minimize downtime, and how to physically connect these devices together with a connector that can survive the lunar environment (dust, extreme cold temperatures) and is capable of both astronaut and robotic operation. The basic components of the micro-grid have to be designed to ensure the system is sustainable, modular, and reconfigurable. An interface to the micro-grid has to be designed that allows for additional technologies, some of which may not yet be fully designed, to easily integrate into the micro-grid concept. This presentation discusses these lunar challenges in some more depth and offers a path forward in designing an evolvable micro-grid to meet the needs of the lunar surface operations and proposes a Universal Micro-grid Interface Converter to connect these dissimilar power sources and mission loads to the micro-grid.

Jeffrey Csank↗
DOE OSTI2026

Computational Design of Interlayers for Thermally Stable Compositionally Graded Coatings on Nickel Alloys

To extend the service life of Ni-based superalloys, refractory metal coatings are often used. However, direct bonding between metals with dissimilar crystal structure promotes brittle intermetallic phase formation. This work presents a computational thermodynamic framework for high throughput design of functionally graded interlayers to suppress deleterious phases that may form at the interlayer. The Thermo-Calc software package was used to screen candidate metallic interlayer elements based on stability of solid-solution phases. Vanadium was identified as a promising interlayer due to its consistent suppression of intermetallic phases. Temperature-dependent phase diagram mapping between 600 and 1000 °C guided selection of a compositional pathway that significantly reduced intermetallic formation compared to directly joining the Ni-based and Nb refractory alloys. Time–temperature–transformation analysis was performed to assess whether equilibrium-predicted phases are kinetically accessible along regions of the graded path where non-solid-solution phases are not fully suppressed. The methodology was further applied to additional Ni-based alloy and coating systems, illustrating its transferability as an approach for rapid computational design of graded interlayers in dissimilar high-temperature materials.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure characteristics of LPBF&HIP fabricated graded composite transition joint between ferritic steel and austenitic stainless steel

Graded composite transition joints (GCTJs) offer a promising alternative to conventional dissimilar metal welds (DMWs) by enabling smooth compositional and microstructural transitions. However, GCTJs fabricated solely through additive manufacturing (AM) face challenges such as heat accumulation, complex parameter control, and elemental segregation. In this study, we propose a novel approach that relies on AM to design a spatially graded structure in one alloy and then employs hot isostatic pressing (HIP) as a diffusion bonding method to join it with a second alloy. Here, this method combines the flexibility of AM with the powder net-shaping advantage of HIP. Specifically, a series of closely packed austenitic stainless steel 304 conical structures were printed using laser powder bed fusion (LPBF) and then combined with ferritic steel P91 powder via HIP. By using electron backscatter diffraction (EBSD), electron probe microanalysis (EPMA), and transmission electron microscopy (TEM) techniques, the microstructure characteristics of the GCTJ of 304&P91, especially the interdiffusion zone (IDZ), have been systematically investigated. The microstructure at the interface transitions from austenite-ferrite (A+F) to austenite-martensite-ferrite (A+M+F), and finally to martensite-ferrite (M+F) due to diffusion. Additionally, the diffusion width between 304 and P91 increases with the volume fraction of P91. This unique design also ensures a gradual transition in both hardness and thermal expansion coefficient from 304 to P91, thereby enabling a smooth gradient in functional properties. Overall, this study proposes a novel approach for fabricating GCTJs and contributes to advancing design concepts in the field of dissimilar metal joining.

Additively manufacturing (AM)↗
DOE OSTI2025

Comparison of removal and spatial mark‐resight models for estimating wild pig density

Density estimation is critical to effectively manage invasive species and elucidate areas of highest concern. For wild pigs (Sus scrofa), the ability to estimate density is complicated because of their variable home range sizes and social structure. Common methods for estimating density (e.g., mark-recapture) may be unsuitable in management applications because additional data needs to be collected before and after management. Removal models offer a suitable alternative to estimate density changes following management and can be applied broadly across areas where management of wild pigs is ongoing. We collected wild pig removal and camera trap data from 25 private properties ranging in size from approximately 0.5 km 2 to 95 km 2 across 3 ecoregions in South Carolina, USA, from 2020–2023. We compared factors affecting consistency and precision of property-level density estimates between removal and spatial mark-resight (SMR) models. In general, excluding 1 large outlier, density estimates from removal models were between 0.60 and 15.85 wild pigs/km 2 (median = 5.34) with a median coefficient of variation (CV) of 0.76 and 95% confidence intervals for the CV between 0.70 and 0.94. Similarly, excluding 1 large outlier, density estimates from SMR were between 0.22 and 30.97 wild pigs/km 2 (median = 5.48) with a median CV of 0.39 and 95% confidence intervals for the CV between 0.38 and 1.20. We found the precision of removal models was affected primarily by the number of wild pigs dispatched in the removal period (3 months) and the ecoregion in which they were removed. None of the covariates, including the number of recaptures (a corresponding measure of sample size), influenced precision of the SMR models, although recaptures did influence the density estimates. At the individual property level, density estimates from our 2 estimators were dissimilar from each other in approximately 80% of instances, although none of the covariates we examined influenced dissimilarity. Our results provide unique insight into how sample size affects density estimates using 2 common methods and into novel SMR models that incorporate both marked and unmarked detections. In addition, the density estimates in this study can be used as a reference for wild pig densities in common land cover types throughout the southeastern United States.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. Here, in the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Correlation between microstructure and residual stress formation in friction stir welded armor steels characterized by neutron diffraction

Friction stir welding (FSW) is a solid-state joining process that minimizes the heat-affected zone (HAZ) compared with fusion-based arc welding, making it well suited for joining martensitic armor steels where hardness and ballistic resistance are critical. This study investigates residual stress formation in three defect-free FSW butt-joint configurations relevant to armored-vehicle fabrication: similar rolled homogeneous armor (RHA–RHA, Case 1), similar high-hardness armor (HHA–HHA, Case 2), and dissimilar HHA–RHA (Case 3) joints produced under temperature-controlled conditions (770 °C). Neutron diffraction was employed to quantify the magnitude and spatial distribution of residual stresses in the longitudinal, transverse, and normal directions and to correlate them with weld microstructure and hardness. Tensile residual stresses were concentrated in the softened HAZ, reaching approximately 300 MPa for Case 2 and 400 MPa for Case 1 (≈50–70 % of the base-metal yield strength; ∼581 MPa for RHA and ∼566 MPa for HHA), while compressive residual stresses dominated the stir zone. The spatial extent of tensile stresses scaled with the width of the softened HAZ, which was largest in the dissimilar HHA–RHA joint and smallest in the HHA–HHA joint. Full-width-at-half-maximum (FWHM) analysis revealed low microstrain in overtempered HAZ regions and high microstrain in the stir zone associated with severe plastic deformation and fresh martensite formation. This work demonstrates that residual stress evolution in FSW of martensitic armor steels is governed not primarily by peak temperature or thermal contraction, as inferred from fusion-welding analogies, but by the competition between transformation-induced volumetric expansion and tempering-induced stress relaxation. The relative dominance of these mechanisms is shown to depend on alloy hardenability and local thermal history, leading to more extensive HAZ softening and broader tensile stress regions in the lower-hardenability RHA steel. These findings establish a transferable mechanistic framework for optimizing solid-state joining strategies in high-strength steels and other transformation-hardening alloys beyond armor applications.

Friction stir welding↗
DOE OSTI2025

Unveiling the dark matter of riverine dissolved organic matter and its role in molecular chemodiversity

Chemodiversity of riverine dissolved organic matter (DOM) plays a crucial role in global elemental cycles and ecosystem function. However, DOM “dark matter”—molecules without assigned specific formulae—remain unexplored in the interpretation of chemodiversity. Here, we systematically investigated the characteristics and drivers of dark matter and its impacts on DOM chemodiversity using 551 river water and sediment samples. Compared to known matter with specific formulae, dark matter exhibited lower molecular weight and diversity, but higher compositional dissimilarity, with dissolved organic carbon (DOC) as the primary driver. Including dark matter into chemodiversity analysis changed mass, diversity, and compositional dissimilarity of DOM from –10.1 to –0.04 %, –0.7 to 4.9 %, and 0.4 to 28.8 % in waters, and from –17.5 to 5.7 %, –10.5 to 19.2 %, and –22.3 to 33.1 % in sediments, respectively. DOC mediated these ecosystem-dependent effects: lower DOC amplified the effects on chemodiversity in waters, whereas in sediments, the effects shifted from negative to positive with changing DOC. Furthermore, ignoring dark matter would overestimate the regulatory role of DOC on sediment DOM chemodiversity. In conclusion, collectively, our findings clarify the influence of dark matter on DOM chemodiversity assessments across environmental gradients, improving understanding of riverine DOM and refining its analytical framework.

Chemodiversity↗