Welding-base metal investigation
Effects of factors associated with aluminum base plate and filler wire on occurrence of weld defects
FILLER↗
SEARCH · Engineering Papers
Results for “filler metal”
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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Heat Transfer Between Surfaces in Contact - the Effect of Low Conductance Interstitial Materials. Part 1 - Experimental Verification of NASA Test Apparatus
Test apparatus for studying convective heat transfer between metallic contacts with interstitial fillers
Fletcher, L. S.↗
Method of making counterrotating aircraft propeller blades
An aircraft propeller blade is constructed by forming two shells of composite material laminates and bonding the two shells to a metallic spar with foam filler pieces interposed between the shells at desired locations. The blade is then balanced radially and chordwise.
Nelson, Joey L.↗
Compression Response of Silicone-Based Composites with Integrated Multifunctional Fillers
Polydimethylsiloxane (PDMS) is known for its exceptional mechanical properties, chemical stability, and flexibility. Recent advancements have focused on developing functional PDMS composites by integrating various functional fillers, including polymers, ceramics, and metals, for advanced applications such as electronics, medical devices, and aerospace. Consequently, there is a growing need to investigate PDMS composites to achieve higher filler loadings offering enhanced mechanical performance. This study addresses this need by utilizing the high molecular weight (MW) PDMS resin we have developed, offering its high elongation capacity of up to >6500%. We incorporated boron (B), hollow glass microballoons (HGMs), and tungsten-coated hollow glass microballoons (WHGMs) into the developed high MW PDMS. The resulting composites demonstrated excellent elastic properties and significant compression resilience (35–80%) and elastic modulus (1.28–10.15 MPa) at high filler loadings (~60 vol.%). Specifically, B/PDMS composites achieved up to 67.6 vol.% of B, HGM/PDMS composites held up to 68.6 vol.% of HGM, and WHGM/PDMS composites incorporated up to 54.0 vol.% of WHGM. These findings highlight the potential of high MW PDMS for developing high-performance PDMS composites suitable for advanced applications such as aerospace, automotive, and medical devices.
36 MATERIALS SCIENCE↗
Plug replaces weld filler as seal in complex casting
Expandable metal plug is inserted to provide a seal to support the mold core with small blocks, referred to as chaplets, during the casting of a complex volute. Weld-warpage and multiple X ray inspection are eliminated by use of this technique.
Goundrey, R. L.↗
Salt Filler For Making Covered Channels
In simple fabrication technique, metal salts used to create such subsurface channels as those for coolant in metallic heat exchanger. Layer of metal deposited on structure by vacuum plasma spraying, sealing channels. Metal salt or salt mixture has melting temperature higher than those of waxes and aluminum and withstands high temperature of plasma spraying. After plasma spraying, salt filler dissolved quickly and easily and flushed away with water or other appropriate solvent, leaving behind covered channels.
Mckechnie, Timothy N.↗
Dual-Purpose Canister Filling Demonstration Project Progress Report at ORNL, 2023
The US DOE Office of Nuclear Energy is investigating the feasibility of direct disposal of dual-purpose canisters (DPCs) in a hypothetical geological repository to offset the potential requirement to repackage spent nuclear fuel (SNF) from existing DPCs into smaller, disposal-ready canisters. Oak Ridge National Laboratory (ORNL) is currently evaluating the feasibility of filling void space in loaded DPCs with an engineered material to prevent a criticality event caused by groundwater/moderator intrusion. Metal alloys are being investigated as a filler material because of their relatively low viscosities when molten, which may facilitate their injection via an existing drainpipe that runs almost the full length of the DPC. ORNL’s strategy for evaluating filler viability includes simulations and physical demonstrations of filling and casting behavior, as well as evaluations of materials for compatibility in the repository environment. Filling of DPCs in this manner is expected to mitigate the risk associated with a post-closure criticality event during the repository performance assessment time frame (10,000 years or greater). Efforts in this fiscal year focused on (1) destructive analysis of experimental filler castings made in FY 2022, (2) a report outlining a conceptual design of a DPC filling facility (Fortner et al., 2023, M3SF 23OR010305044/ ORNL/SPR-2023/2921, May 31, 2023), (3) a report on affected features, events, and processes (FEPs) due to DPC filling (Price et al., 2023, M3SF-23SN010305093, issuance pending), (4) developing and testing a more practical alloy filler based upon a Sn-Al eutectic, and (5) modeling the heating and cooling dynamics of a DPC subjected to molten metal filling. The preliminary results from each of these tasks support the feasibility of filling DPCs with metal as a strategy against the possibility of criticality in the repository. The FY 2022 casting was found to penetrate even very small orifices in the mold and internal structures. Preliminary testing of the Sn-Al eutectic indicate little interaction of the melt with Zircaloy cladding. Thermal modelling shows that a filled DPC will cool to manageable temperatures within 2-3 days, which is likely manageable in a facility.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Carbon-Nanotube-Carpet Heat-Transfer Pads
Microscopic thermal-contact pads that include carpet-like arrays of carbon nanotubes have been invented for dissipating heat generated in integrated circuits and similarly sized single electronic components. The need for these or other innovative thermal-contact pads arises because the requisite high thermal conductances cannot be realized by scaling conventional macroscopic thermal-contact pads down to microscopic sizes. Overcoming limitations of conventional thermal-contact materials and components, the carbon-nanotube thermal-contact pads offer the high thermal conductivities needed to accommodate the high local thermal power densities of modern electronic circuits, without need for large clamping pressures, extreme smoothness of surfaces in contact, or gap-filling materials (e.g., thermally conductive greases) to ensure adequate thermal contact. Moreover, unlike some conventional thermal-contact components, these pads are reusable. The figure depicts a typical pad according to the invention, in contact with a rough surface on an electronic component that is to be cooled. Through reversible bending and buckling of carbon nanotubes at asperities on the rough surface, the pad yields sufficiently, under relatively low contact pressure, that thermal contact is distributed to many locations on the surface to be cooled, including valleys where contact would not ordinarily occur in conventional clamping of rigid surfaces. Hence, the effective thermal-contact area is greater than that achievable through scaling down of a macroscopic thermal-contact pad. The extremely high longitudinal thermal conductivities of the carbon nanotubes are utilized to conduct heat away from potential hot spots on the surface to be cooled. The fibers protrude from a layer of a filler material (Cu, Ag, Au, or metal-particle- filled gels), which provides both mechanical support to maintain the carbon nanotubes in alignment and thermal conductivity to enhance the diffusion of concentrated heat from the nanotubes into the larger adjacent volume of a heat sink. The array of carbon nanotubes, the filler material, and the heat sink are parts of a unitary composite structure that is fabricated as follows: 1. Using techniques that have been reported previously, the array of substantially perpendicularly oriented carbon nanotubes is grown on a metal, silicon, or other suitable thermally conductive substrate that is intended to become the heat sink. 2. By means of chemical vapor deposition, physical vapor deposition, plasma deposition, ion sputtering, electrochemical deposition, or casting from a liquid phase, some or all of the interstitial volume between carbon nanotubes is filled with the aforementioned layer of mechanically supporting, thermally conductive material. 3. To cause the carbon nanotubes to protrude the desired length from the filler material, an outer layer of filler is removed by mechanical polishing, chemical mechanical polishing, wet chemical etching, electrochemical etching, or dry plasma etching.
Li, Jun↗
Understanding Thermal Transport in Polymer –Silver Nanowire Composites
Understanding thermal transport across filler-polymer interfaces and filler-filler contacts within polymer composites is of great importance for better thermal design of the composites that are widely used in high-performance heat exchangers, energy storage devices, and flexible electronics. Over the past several decades, considerable progress has been made in improving the thermal conductivity of polymer composites, but several key questions concerning the influence of interfacial thermal resistance, or Kapitza resistance, still remain. Firstly, the thermal properties of these composites are highly dependent on thermal transport through the filler network and its contacts. For metallic nanofillers, the thermal conductivity is often estimated using the Wiedemann-Franz law based on electrical conductivity; however, it remains a question whether the Wiedemann-Franz law still holds at nanoscale contacts. Through investigation of silver nanowires of varying sizes, we were able to demonstrate that the Lorenz number for silver nanowire increases with decreasing nanowire diameter. Examination of the corresponding electrical and thermal conductivities indicate that these changes are due to that the relative contribution of phonons becomes more significant as a result of elastic stiffening. Furthermore, we show that for silver nanowires, the contact thermal resistance is ~8 times lower than that of multi-walled carbon nanotube (MWCNT) of similar diameters. Additionally, through systematic studies of electrospun polymer-silver nanowire composite nanofibers, we investigated the impact of interface morphology on the thermal conductivity enhancement of the composite system and probed the value of the Kapitza resistance for individual polymer-filler interfaces. For polymer nanofibers containing continuous, single silver nanowires, the thermal conductivity increases linearly with increasing volume fraction of silver, which is consistent with the prediction of percolation theory for samples above the percolation limit. By comparing this linear trend to the measured thermal conductivities of composite nanofibers with more complex structures, we were able to determine the resistance associated with any additional polymer-filler boundaries. In doing so we find that the thermal boundary resistance for polyvinylpyrrolidone (PVP)–silver interfaces is significantly lower than that of comparable polymer-MWCNT composite systems.Together our studies provide new insights into thermal transport in polymer nanocomposites and should help facilitate the design of high performance polymeric thermal interface material.
Thermal transport↗
Understanding Thermal Transport in Polymer - Silver Nanowire Composites
Understanding thermal transport across filler-polymer interfaces and filler-filler contacts within polymer composites is of great importance for better thermal design of the composites that are widely used in high-performance heat exchangers, energy storage devices, and flexible electronics. Over the past several decades, considerable progress has been made in improving the thermal conductivity of polymer composites, but several key questions concerning the influence of interfacial thermal resistance, or Kapitza resistance, still remain. Firstly, the thermal properties of these composites are highly dependent on thermal transport through the filler network and its contacts. For metallic nanofillers, the thermal conductivity is often estimated using the Wiedemann-Franz law based on electrical conductivity; however, it remains a question whether the Wiedemann-Franz law still holds at nanoscale contacts. Through investigation of silver nanowires of varying sizes, we were able to demonstrate that the Lorenz number for silver nanowire increases with decreasing nanowire diameter. Examination of the corresponding electrical and thermal conductivities indicate that these changes are due to that the relative contribution of phonons becomes more significant as a result of elastic stiffening. Furthermore, we show that for silver nanowires, the contact thermal resistance is ~8 times lower than that of multi-walled carbon nanotube (MWCNT) of similar diameters. Additionally, through systematic studies of electrospun polymer-silver nanowire composite nanofibers, we investigated the impact of interface morphology on the thermal conductivity enhancement of the composite system and probed the value of the Kapitza resistance for individual polymer-filler interfaces. For polymer nanofibers containing continuous, single silver nanowires, the thermal conductivity increases linearly with increasing volume fraction of silver, which is consistent with the prediction of percolation theory for samples above the percolation limit. By comparing this linear trend to the measured thermal conductivities of composite nanofibers with more complex structures, we were able to determine the resistance associated with any additional polymer-filler boundaries. In doing so we find that the thermal boundary resistance for polyvinylpyrrolidone (PVP)–silver interfaces is significantly lower than that of comparable polymer-MWCNT composite systems. Together our studies provide new insights into thermal transport in polymer nanocomposites and should help facilitate the design of high performance polymeric thermal interface material.
Matthew L. Fitzgerald↗
Platable Filler And Sealant
Mixture of facsimile compound and silver powder forms positive seal in small hole in metal sheet. Filled hole plated over by standard electrodeposition. Compound does not deteriorate in high plating-bath temperatures, unlike wax and other fillers. Provides surface to which plated metals readily adhere.
Heerman, Todd R.↗
Evaluation of zirconia, thoria and zirconium diboride for advanced resistojet use
A literature survey was conducted to collect material properties data on all advanced high temperature materials. Three of these, Y2O3-stabilized ZrO2, ThO2, and ZrB2 with additives of C and SiC were selected for further study. Stabilized ZrO2 and ThO2 were found to have higher temperature oxidation resistance than any metal and great potential for use in advanced biowaste resistojets. ZrO2 has a lower electrical resistivity and sublimation and a higher creep endurance strength. ZrO2 and ThO2 tubular heat exchangers, electrically heated indirectly, were evaluated in short tests to about 1900 K in flowing CO2. ZrO2 was subjected to N2, H2, H2O and vacuum as well. X-ray diffraction and fluorescence analyses were made. The metal-to-ceramic seal technology for ZrO2 and ThO2 was developed using chemical vapor deposition of tantalum for metallizing and 82 Au - 18 Ni filler braze.
Page, R. J.↗
Fabrication of Lightweight Radiation Shielding Composite Materials by Field Assisted Sintering Technique (FAST)
Advances in radiation shielding technologies are needed to protect humans and electronic components from all threats of space radiation over long durations. In this paper, we report on the use of the innovative and novel fabrication technology known as Field Assisted Sintering Technology (FAST) to fabricate lightweight material with enhanced radiation shielding strength to safeguard humans and electronics suitable for next generation space exploration missions. The base materials we investigated were aluminum (Al), the current standard material for space hardware, and Ultra-High Molecular Weight Polyethylene (UHMWPE), which has high hydrogen content and resistance to nuclear reaction from neutrons, making it a good shielding material for both gamma radiation and particles. UHMWPE also has high resistance to corrosive chemicals, extremely low moisture sensitivity, very low coefficient of friction, and high resistance to abrasion. We reinforced the base materials by adding high density (ie, high atomic weight) metallic material into the composite. These filler materials included: boron carbide (B4C), tungsten (W), tungsten carbide (WC) and gadolinium (Gd).
Prasad, Narasimha↗
Improved interfacial li-ion transport in composite polymer electrolytes via surface modification of LLZO
Composite polymer electrolytes that incorporate ceramic fillers in a polymer matrix offer mechanical strength and flexibility as solid electrolytes for lithium metal batteries. However, fast Li + transport between polymer and Li + -conductive filler phases is not a simple achievement due to high barriers for Li + exchange across the interphase. This study demonstrates how modification of Li 7 La 3 Zr 2 O 12 (LLZO) nanofiller surfaces with silane chemistries influences Li + transport at local and global electrolyte scales. Anhydrous reactions covalently link amine-functionalized silanes [(3-aminopropyl)triethoxysilane (APTES)] to LLZO nanoparticles, which protects LLZO in air. APTES functionalization lowers the poly (ethylene oxide) (PEO)-LLZO interphase resistance to half that of unmodified LLZO and increases effective Li + transference number, while insulating Al 2 O 3 completely blocks ion exchange and lowers transference number and conductivity in PEO-lithium bis(trifluoromethanesulfonyl)imide (LiTFSI)-LLZO composites. Modeling an inner resistive interphase between LLZO and PEO surrounded by an outer conductive interphase explains non-linear conductivity trends. Solid-state 7 Li & 6 Li nuclear magnetic resonance shows Li + only exchanges between PEO-LiTFSI and some LLZO interphase, with no appreciable Li + transport through bulk LLZO. Surface functionalization is a promising path toward lowering the polymer-ceramic interphase resistance. This work demonstrates that local changes in Li + transport affect macroscopic performance, highlighting the intricate relationships between all interfaces in inherently heterogeneous composite polymer electrolytes.
25 ENERGY STORAGE↗
Compatibility of molten salts with advanced solar dynamic receiver materials
Metal-coated graphite fibers are being considered as a thermal conductivity enhancement filler material for molten salts in solar dynamic thermal energy storage systems. The successful metal coating chosen for this application must exhibit acceptable wettability and must be compatible with the molten salt environment. Contact angle values between molten lithium fluoride and several metal, metal fluoride, and metal oxide substrates have been determined at 892 C using a modification of the Wilhelmy plate technique. Reproducible contact angles with repeated exposure to the molten LiF indicated compatibility.
Jaworske, D. A.↗
Factors affecting direct lightning strike damage to fiber reinforced composites: A review
In recent years, Carbon Fiber Reinforced Plastics (CFRP) or Glass Fiber Reinforced Plastics (GFRPs) have become a very common material for aircraft and wind turbine structures. These structures are often protected from lightning strikes using conventional metal-based protective films/foils. Non-conventional, non-metallic lightning strike protection (LSP) technologies have not yet been fully realized, but research on non-conventional LSP systems for CFRPs has gained momentum in the last few years. The discovery of new structural conductive materials and improvements in the processing of carbon nano-filler based composites have challenged the conventional metal-based LSP systems by providing the potential for lightweight, non-metallic alternatives. However, a major challenge in using non-conventional LSP is the complex nature of a lightning strike event and its complicated thermal and mechanical impact on CFRP structures. Understanding the direct effect of a lightning strike on a CFRP structure requires understanding multiple transient loads, such as electrical, thermal, magnetic, acoustics, shock, and inertia. This review article focuses on new findings and discusses the complex direct effects of lightning on CFRPs. Specifically, the focus is to find the important factors that regulate and control the damage to FRPs are classified and discussed with the help of available literature based on experimental results. Finally, possibilities and limitations to these new findings are discussed.
36 MATERIALS SCIENCE↗
An examination of the precipitation behavior of proton irradiated dual phase 308L weldment filler materials
Voids, G phase particles, and Ni-Si rich clusters in proton irradiated dual phase 308L groove filler of a SA508–304 L dissimilar metal weldment are analyzed using advanced characterization techniques. These weldments are often used in light water nuclear reactors and are subject to enhanced corrosion and associated stress corrosion cracking (SCC). Radiation damage is known to accelerate SCC. Ni-Si enriched clusters were observed in proton irradiated γ austenite, while G phase M 6 Ni 16 Si 7 (where M transition metal element) precipitates were observed in proton irradiated δ ferrite. Compositional analysis of the G phase precipitates and Ni-Si clusters from STEM-EDS and APT are compared. Unlike G phase particles in proton irradiated δ ferrite, Ni-Si clusters in proton irradiated γ austenite are not rich in Mn. Both STEM-EDS and APT line-scan profiles of the Ni-Si clusters show that the Fe and Cr concentration gradient between matrix γ austenite and the Ni-Si clusters is not as sharp as those between matrix δ ferrite and G phase. Further, HR-STEM imaging indicates that the lattice parameter of the Ni-Si clusters is commensurate with γ austenite and the clusters do not represent the precipitation of a second phase. Finally, our analysis demonstrates the density and volume fraction of G phase particles and the density of voids scales with proton irradiation damage and the energy to recoils.
308L groove filler↗
Modified microstructures in proton irradiated dual phase 308L weldment filler material
In this study, the effect of proton irradiation on the microstructure of δ ferrite—γ austenite mixed phase 308L filler material in a 508–304 dissimilar metal weldment was investigated over a depth of 0 to 10 µm. Ni–Si–Mn G-phase precipitates were observed with SEM and TEM in δ ferrite but not in γ austenite. Our density functional theory based calculations show that the G/Fe interface energy in δ-Fe is significantly lower than that in γ-Fe (0.35 versus 1.25 J/m 2 ), which provides a thermodynamics-based explanation for our experimental observations of preferential formation of G-phase in δ ferrite. STEM-EDS, TEM dark field imaging, and diffraction patterns confirmed the Ni–Si–Mn enriched precipitates were G-phase precipitates with a stoichiometry of Mn 6 Ni 16 Si 7 . Intragranular voids and Ni–Si enriched clusters were observed in irradiated γ austenite. Additionally, Ni and Si segregation was observed along the void interfaces. In both cases, Ni–Si clusters and segregation to voids, selected area diffraction patterns did not reveal the existence of a second phase. Proton irradiation induced Cr depletion and Si and Ni enrichment at γ-γ austenite grain boundaries that was characterized with STEM/EDS.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗