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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 NTRS2013

Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication in support of the 2014 launch of the Orion MPCV.

Alcorn, John↗
DOE OSTI2026

Sliding friction and wear behavior of nuclear graphite in high temperature inert environment: Influence of contact load, speed and temperature

Repeated dynamic interactions of graphitic components in pebble-bed gas-cooled nuclear reactors can cause abrasive wear-induced pebble surface damage, generate hazardous fine graphite debris, and alter fuel circulation dynamics due to changes in friction behavior. Comprehensive tribological characterization of nuclear graphitic materials in conditions relevant to reactor operation is needed to assess reactor long-term safety and performance. This work reports sliding friction and wear behavior of self-mated nuclear graphite ET-10 at various elevated temperatures (650 °C and 750 °C), sliding speeds (1 and 10 mm/s) and contact loads (20 and 40 N) in a controlled argon environment. The results revealed nonmonotonic frictional behavior with a higher running-in coefficient of friction (COF) followed by a lower steady-state COF, as a result of transition from two-body abrasion to three-body abrasion along with formation of a tribofilm. A key finding of this work is the sensitivity of the running-in COF to experimental conditions; maximum running-in values were lower at either elevated temperature (0.52–0.54) or reduced sliding speed (0.51–0.54). Conversely, the steady-state COF remained invariant at approximately 0.3 across all tested parameters. Transmission electron microscopy revealed a 0.5–2.0 μm thick nanocrystalline tribofilm that was thought to be formed by the compaction of the graphitic wear debris on the contact surface during the sliding process. The nanocrystalline nature of the tribofilm was further confirmed by Raman spectroscopy. As a result, the combination of tribological testing and morphological characterization provided a mechanistic understanding of the frictional behavior of nuclear graphite upon sliding.

Friction↗
DOE OSTI2026

Designing Thermomechanically Stable Nanocrystalline Alloys for Low Friction and Wear: A Perspective

In this Perspective, we discuss recent work and future trends on the usage of thermomechanically stable and selflubricating nanocrystalline (NC) alloys for low friction and wear applications. The theoretical underpinnings and mechanistic framework for attaining and maintaining low friction and wear in metal contacts are presented. Initial work on stress, time, and temperature-dependent changes in friction and wear in NC alloys validates the models, demonstrating lower friction from decreased interfacial strength, contact pressure, sliding speed, and temperature and increased roughness and material hardness. Subsequent work reveals that NC Pt−Au, metal nitrides, complex-concentrated, and high-entropy alloys come with additional stabilization factors such as low-friction carbon tribofilms and oxide/amorphous−crystalline layers but are still susceptible to destabilization factors including irradiation and adverse environmental conditions.

alloys↗
NASA NTRS1952

Friction and Surface Damage of Several Corrosion-resistant Materials

Friction and surface damage of several materials that are resistant to corrosion due to liquid metals was studied in air. The values of kinetic friction coefficient at low sliding velocities and photomicrographs of surface damage were obtained. Appreciable surface damage was evident for all materials tested. The friction coefficients for the combinations of steel, stainless steel, and monel sliding against steel, stainless steel, nickel, Iconel, and Nichrome ranged from 0.55 for the monel-Inconel combination to 0.97 for the stainless-steel-nickel combination; for steel, stainless steel, monel, and tungsten carbide against zirconium, the friction coefficient was approximately 0.47. Lower coefficients of friction (0.20 to 0.60) and negligible surface failure at light loads were obtained with tungsten carbide when used in combination with various plate materials.

ONTACT SURFACES, SLIDING↗
NASA NTRS2021

Skin Friction Extracted from Surface Pressure in Incident Shock-Wave/Boundary-Layer Interaction

High-resolution skin-friction fields are extracted from pressure-sensitive paint (PSP) data obtained in shock-wave/boundary-layer interaction (SWBLI). The method of extracting skin friction from surface pressure is described, including the fundamental relation between skin friction and surface pressure, the variational method, error analysis, and an approximate iterative method. The proposed method is based on a coupling relation between skin friction and surface pressure, where the boundary enstrophy flux is suitably modeled or approximated. This method is applied to unsteady PSP data obtained in incident SWBLIs at Mach 2.5 for different Reynolds numbers, revealing the skin-friction structures of the flows: particularly, the separation bubble induced by the incident shock wave. The extracted results are in good agreement with the data obtained by the surface-stress-sensitive film.

skin friction↗
DOE OSTI2024

Physics informed neural network can retrieve rate and state friction parameters from acoustic monitoring of laboratory stick-slip experiments

Various machine learning (ML) and deep learning (DL) techniques have been recently applied to the forecasting of laboratory earthquakes from friction experiments. The magnitude and timing of shear failures in stick-slip cycles are predicted using features extracted from the recorded ultrasonic or acoustic emission (AE) signals. In addition, the Rate and State Friction (RSF) constitutive laws are extensively used to model the frictional behavior of faults. In this work, we use data from shear experiments coupled with passive acoustic (variance, kurtosis, and AE rate) interleaved with active source ultrasonic monitoring (transmitted wave amplitude) to develop physics-informed neural network (PINN) models incorporating the RSF law and AE rate generation equation with wave amplitude serving as a proxy for friction state variable. This PINN framework allows learning RSF parameters from stick-slip experiments rather than measuring them through a series of velocity step experiments. We observe that when the stick-slip cycles are irregular, the PINN models outperform the data-driven DL models. Transfer learning (TL) PINN models are also developed by pre-training on data collected at one normal stress level followed by forecasting shear failures and retrieving RSF parameters at other stress levels (i.e., with different recurrence intervals) after retraining on a limited amount of new data. Our findings suggest that TL models perform better compared to standalone models. Both standalone and TL PINN-estimated RSF parameters and their ground truth values show excellent agreements thus demonstrating that RSF parameters can be retrieved from laboratory stick-slip experiments using the corresponding acoustic data and that the transmitted wave amplitude provides a good representation of the evolving frictional state during stick-slips.

58 GEOSCIENCES↗
DOE OSTI2025

Using system identification in modeling the yaw response of tail fins for small wind turbines with bearing friction

Here, we describe three main developments of our previous study of the nonlinear yaw dynamics of the tail fins for small wind turbines [Khedr et al., J. Renewable Sustainable Energy 16, 053305 (2024)]. First, the model constants derived from archived computational and experimental studies are adjusted by employing system identification (SI) to maximize the model's agreement with wind tunnel tests. This adjustment was done for high wind speeds, where yaw bearing friction can be ignored. When starting a turbine at low wind speed, however, friction can become important. Our second development is to implement a model for the frictional resistive torque and use SI to maximize its accuracy. These developments used wind tunnel experiments on generic delta, elliptical, and rectangular planforms that were described by Khedr et al. [J. Renewable Sustainable Energy 16, 053305 (2024)]. Since the aerodynamic and friction models employ a large number of constants, we describe ways to constrain the values using linearized solutions of the response equations for small and large yaw angles. Third, we test the generality of the aerodynamic and friction modeling using the complex planform from a commercial small turbine, for which limited theoretical and computational guidance is available in selecting the model constants. The model implemented with SI is shown to provide an accurate description of the yaw response of the complex planform. Guidelines are given for the use of wind tunnel tests to determine the model constants for tail fins of any planform.

17 WIND ENERGY↗
NASA NTRS1973

Friction-induced surface activity of some hydrocarbons with clean and oxide-covered iron

Sliding friction studies were conducted on a clean and oxide-covered iron surface with exposure of that surface to various hydrocarbons. The hydrocarbons included ethane, ethylene ethyl chloride, methyl chloride, and vinyl chloride. Auger cylindrical mirror analysis was used to follow interactions of the hydrocarbon with the iron surface. Results with vinyl chloride indicate friction induced surface reactivity, adsorption to surface oxides, friction sensitivity to concentration and polymerization. Variation in the loads employed influence adsorption and accordingly friction. In contrast with ethyl and vinyl chloride, friction induced surface reactivity was not observed with ethane and ethylene.

Buckley, D. H.↗
NASA NTRS1973

Local skin friction coefficients and boundary layer profiles obtained in flight from the XB-70-1 airplane at Mach numbers up to 2.5

Boundary-layer and local friction data for Mach numbers up to 2.5 and Reynolds numbers up to 3.6 x 10 to the 8th power were obtained in flight at three locations on the XB-70-1 airplane: the lower forward fuselage centerline (nose), the upper rear fuselage centerline, and the upper surface of the right wing. Local skin friction coefficients were derived at each location by using (1) a skin friction force balance, (2) a Preston probe, and (3) an adaptation of Clauser's method which derives skin friction from the rake velocity profile. These three techniques provided consistent results that agreed well with the von Karman-Schoenherr relationship for flow conditions that are quasi-two-dimensional. At the lower angles of attack, the nose-boom and flow-direction vanes are believed to have caused the momentum thickness at the nose to be larger than at the higher angles of attack. The boundary-layer data and local skin friction coefficients are tabulated. The wind-tunnel-model surface-pressure distribution ahead of the three locations and the flight surface-pressure distribution ahead of the wing location are included.

Fisher, D. F.↗
NASA NTRS1973

Friction induced surface activity of some simple organic chlorides and hydrocarbons with iron.

Sliding friction studies were conducted on an iron surface with exposure of that surface to various hydrocarbons and organic chlorides. The hydrocarbons included ethane, ethylene, ethyl chloride, methyl chloride and vinyl chloride. Auger cylindrical-mirror analysis was used to follow interactions of the hydrocarbon and organic chlorides with the iron surface. Results with vinyl chloride indicate friction-induced surface reactivity, adsorption to surface oxides, friction sensitivity to concentration and polymerization. Variation in the loads employed influence adsorption and, accordingly, friction. Unlike results with ethyl and vinyl chloride, friction-induced surface reactivity was not observed with ethane and ethylene.

Buckley, D. H.↗
NASA NTRS1975

Friction and wear of tin and tin alloys from minus 100 C to 150 C

Sliding friction experiments were conducted with an iron (110) single-crystal pin sliding on single and polycrystalline tin and tin alloys. Specimens were examined at various ambient temperatures from -100 to 150 C. Applied loads varied from 1 to 50 grams, and sliding velocity was constant at 0.7 mm/min. Results indicate that the crystal transformation of tin influences the friction coefficient. Friction was higher for the diamond structure (gray tin) than it was for the body-centered tetragonal structure (white tin). Bismuth arrested the crystal transformation, which resulted in constant friction over the temperature range -100 to 150 C. Both copper and aluminum enhanced the kinetics of transformation, with aluminum producing a nearly twofold change in friction with the crystal transformation.

Buckley, D. H.↗
NASA NTRS1975

Surface friction of rock in terrestrial and simulated lunar environments

The conventional probe-on-the rotating-disk concept was used to determine the surface friction in mineral probe/specimen interfaces. Nine rocks or minerals and two stainless steels were tested in both new (NT) and same track (ST) tests under three different pressure environments-atmospheric, UHV, and dry nitrogen. Each environment was further subdivided into two testing conditions, that is, ambient and elevated (135 C) temperatures. In NT tests, friction was the lowest in an atmospheric pressure condition for all rock types and increased to the largest in UHV ambient condition except for pyroxene and stainless steel. Friction values measured in dry nitrogen ambient condition lie between the two extremes. Heating tends to increase friction in atmospheric and dry nitrogen environment but decreases in UHV environment with the exception of stainless steel, basalt, and pyroxene. In ST tests, friction was the lowest in the first run and increased in subsequent runs except for stainless steel where the reverse was true. The increases leveled off after a few runs ranging from the second to the seventh depending on rock types.

Roepke, W. W.↗
NASA NTRS1976

Direct measurements at Mach 6 of turbulent skin-friction reduction by injection from single and multiple flush slots

The surface skin-friction reduction downstream of one to four successive flush slots injecting at an angle of 10 deg into a turbulent Mach 6 boundary layer has been determined from direct measurements of surface shear. Increasing the number of succeeding slots increases the skin-friction reduction, but this trend reverses at high injection rates. The incremental improvement in skin-friction reduction decreases with increasing number of slots. Comparison with previously reported step slot data indicates that step slots with tangential injection are more effective in reducing skin friction than the present flush slot configuration. Finite-difference predictions are in reasonable agreement with skin-friction and boundary-layer profile data.

Srokowski, A. J.↗
NASA NTRS1977

Studies of friction and wear characteristics of various wires for wire-brush skids

The friction and wear characteristics of 22 types and sizes of wires for potential use in wire-brush skids were studied. These characteristics were determined by placing brushes made from candidate wires on a belt sander whose moving belt simulated landing roll-out distance. At the same time, the drag force and wear behavior were monitored. Data were obtained over distances up to 3048 m (10,000 ft) at preselected bearing pressures of 172 to 1034 kPa (25 to 150 psi). In general, the friction coefficient developed by the candidate wires was found to be independent of bearing pressure and ranged between 0.4 and 0.6 under the test conditions of this investigation. The friction coefficient was not degraded when the surface was wetted and appears to be independent of wire diameter except perhaps when wire size is relatively large compared with the surface asperities. Generally, the high friction demonstrated by the soft materials was accompanied by high wear rates; conversely, the hard materials provided greater wear resistance but offered lower friction. For all test wires, the wear was shown to increase with increasing bearing pressure, in general, for the same bearing pressure, wear increased with increasing wire diameter and decreased when the surface was wetted.

Dreher, R. C.↗
NASA NTRS1977

Friction and wear behavior of single-crystal silicon carbide in contact with titanium

Sliding friction experiments were conducted with single crystal silicon carbide in sliding contact with titanium. Results indicate that the friction coefficient is greater in vacuum than in argon and that this is due to the greater adhesion or adhesive transfer in vacuum. Thin films of silicon carbide transferred to titanium also adhered to silicon carbide both in argon at atmospheric pressure and in high vacuum. Cohesive bonds fractured on both the silicon carbide and titanium surfaces. The wear debris of silicon carbide created by fracture plowed the silicon carbide surface in a plastic manner. The friction characteristics of titanium in contact with silicon carbide were sensitive to the surface roughness of silicon carbide, and the friction coefficients were higher for a rough surface of silicon carbide than for a smooth one. The difference in friction results was due to plastic deformation (plowing of titanium).

Miyoshi, K.↗
NASA NTRS1977

Friction and deformation behavior of single-crystal silicon carbide

Friction and deformation studies were conducted with single-crystal silicon carbide in sliding contact with diamond. When the radius of curvature of the spherical diamond rider was large (0.3), deformation of silicon carbide was primarily elastic. Under these conditions the friction coefficient was low and did not show a dependence on the silicon carbide orientation. Further, there was no detectable cracking of the silicon carbide surfaces. When smaller radii of curvature of the spherical diamond riders (0.15 and 0.02 mm) or a conical diamond rider was used, plastic grooving occured and the silicon carbide exhibited anisotropic friction and deformation behavior. Under these conditions the friction coefficient depended on load. Anisotropic friction and deformation of the basal plane of silicon carbide was controlled by the slip system. 10101120and cleavage of1010.

Miyoshi, K.↗
NASA NTRS1978

Friction and wear of polyethylene oxide polymer having a range of molecular weights

Sliding friction and wear experiments were conducted at light loads (25 to 250 g) with various molecular weights of the polyethylene oxide polymer sliding on itself and iron. Results of the experimental investigation indicate that: (1) the coefficient of friction for the polymer decreases with increasing molecular weight; (2) friction coefficient is higher for the polymer sliding on itself than it is for the polymer sliding on iron; (3) at sufficiently high loads localized surface melting occurs and the friction coefficient is the same for the polymer sliding on itself and iron; (4) fracture cracks develop in the sliding wear track at higher but not lower sliding velocities, reflecting a strain rate sensitivity to crack initiation, and (5) the friction coefficient for the polymer sliding on iron increases with the formation of a polymer film on the iron surface.

Buckley, D. H.↗
NASA NTRS1978

Direct measurements and analysis of skin friction and cooling downstream of multiple flush-slot injection into a turbulent Mach 6 boundary layer

Experiments were conducted to determine the reduction in surface skin friction and the effectiveness of surface cooling downstream of one to four successive flush slots injecting cold air at an angle of 10 deg into a turbulent Mach 6 boundary layer. Data were obtained by direct measurement of surface shear and equilibrium temperatures, respectively. Increasing the number of slots decreased the skin friction, but the incremental improvement in skin-friction reduction decreased as the number of slots was increased. Cooling effectiveness was found to improve, for a given total mass injection, as the number of slots was increased from one to four. Comparison with previously reported step-slot data, however, indicated that step slots with tangential injection are more effective for both reducing skin friction and cooling than the present flush-slot configuration. Finite-difference predictions are in reasonable agreement with skin-friction data and with boundary-layer profile data.

Howard, F. G.↗