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At least 1,189 records · Page 66
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Use of friction stir processing to synthesize nanocrystalline, grain boundary segregating Fe-Ti alloys

Grain boundary segregating alloys, a class of alloys designed such that nanocrystalline grain sizes are thermodynamically stabilized by the presence of high segregation energy solutes at the grain boundaries, are typically produced through geometrically limited processing techniques such as equal channel angular extrusion or thin film sputtering. Here, this study explores the use of friction stir processing (FSP) as a novel means of studying and producing these alloys using a test system of Fe-6at%Ti. Spot FSPs with a range of processing parameter sets were produced on bulk, coarse grained bars of material and optimal parameters were identified. Microscopy identified a range of processed materials which achieved nanocrystalline grains on the order of 100 nm, delineating a critical window of processing parameters which limit heat input while inducing sufficient plastic deformation for grain refinement. The finest grained nanocrystalline Fe-Ti achieved a hardness of 7.68 GPa, a significant increase in hardness over pure Fe with a similar microstructure due to increased dislocation density from FSP as well as several strengthening mechanisms produced through the presence and segregation of Ti. These results demonstrated the feasibility of using FSP to produce nanocrystalline grain boundary segregating alloys.

Fe alloys↗
DOE OSTI2026

Understanding the effect of friction stir processing on electrical steel: Microstructural changes and mechanical transformations

Raising Si beyond 3.5 wt% reduces core loss but embrittles electrical steels, constraining processing and application. Here we assess friction stir processing (FSP) as a solid‑state route to enable Fe–4.0 wt% Si with improved mechanical performance. Temperature‑controlled FSP with a PcBN tool produced a defect‑free processed zone. SEM/EBSD revealed dynamic recrystallization and grain refinement from an average 110 μm in the base material to ∼20 μm in the processed region, with ∼ 80% of grains < 40 μm and a reduction in high‑angle boundary fraction to ∼65% (vs >85% in the base). Comparative mechanical property analysis shows a moderate increase in yield strength in FSP samples relative to the base material, with a significant improvement in ductility (∼35–50%). Post‑fracture EBSD identified 60° twin boundaries in the base while sub-grain formation with elevated KAM in the FSP sample. Fractography revealed a shift from quasi‑cleavage in the Base-faceted planes with river patterns, steps, and occasional secondary cracks—to ductile micro void coalescence after FSP. Following FSP, the material retains soft‑magnetic behavior, with modest shifts in saturation magnetization consistent with grain refinement and stored strain, accompanied by a clear gain in formability. These results indicate that FSP provides a viable route to deploy higher‑Si electrical steels with concurrent gains in strength and ductility.

Electrical steel↗
DOE OSTI2022

Porosity evolution during heating of copper made from powder by friction extrusion

Here, friction extrusion was used to compact and extrude solid copper rod from feedstock powders. Following extrusion, considerable porosity was observed throughout the extrudate cross section due to the entrained porosity in the feedstock material and the extrusion process. The thermal stability of the extrudate was investigated via a series of heat treatments. Porosity evolution exhibited three distinct stages—an unchanged plateau (0°C–300°C) followed by an abrupt increase (400°C–500°C) and ultimately a reduction, as the temperature increases (>500°C). The peak porosity measured was ~25%. The underlying driving force for pore evolution is described as the competition between the internal pore pressure, material strength, and sintering kinetics, as a function of temperature. The observed porosity evolution and driving force are not expected to be limited to copper. Thus, this manuscript reveals an important consideration regarding elevated-temperature thermal stability as advanced manufacturing methods involving direct powder extrusion are explored.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Force reduction of friction stir welding and processing of steel

Friction stir welding and processing (FSW&P) is considered as a new fabrication method for canisters and repair of existing dry cask storage system canisters (generally made of austenitic stainless steel). Low heat input compared to fusion joining processes and grain refinement associated with low-temperature FSW&P result in a material with improved mechanical properties and equivalent generalized corrosion performance relative to the base metal. But FSW&P of austenitic stainless steel requires significant tool forge axis force to produce a weld (or a run). Exploratory runs utilizing forge axis force control were conducted to investigate the minimum force required to achieve defect-free runs. The correlation between forge axis force and resultant plunge depth was also investigated. Furthermore, detailed microstructural characterization was conducted to display the microstructural variation within the nugget zone.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Tribocatalytically-activated formation of protective friction and wear reducing carbon coatings from alkane environment

Minimizing the wear of the surfaces exposed to mechanical shear stresses is a critical challenge for maximizing the lifespan of rotary mechanical parts. In this study, we have discovered the anti-wear capability of a series of metal nitride-copper nanocomposite coatings tested in a liquid hydrocarbon environment. The results indicate substantial reduction of the wear in comparison to the uncoated steel substrate. Analysis of the wear tracks indicates the formation of carbon-based protective films directly at the sliding interface during the tribological tests. Raman spectroscopy mapping of the wear track suggests the amorphous carbon (a-C) nature of the formed tribofilm. Further analysis of the tribocatalytic activity of the best coating candidate, MoN-Cu, as a function of load (0.25–1 N) and temperature (25 °C and 50 °C) was performed in three alkane solutions, decane, dodecane, and hexadecane. Results indicated that elevated temperature and high contact pressure lead to different tribological characteristics of the coating tested in different environments. The elemental energy dispersive x-ray spectroscopy analysis and Raman analysis revealed formation of the amorphous carbon film that facilitates easy shearing at the contact interface thus enabling more stable friction behavior and lower wear of the tribocatalytic coating. These findings provide new insights into the tribocatalysis mechanism that enables the formation of zero-wear coatings.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Curvature effect on tearing modes in presence of neoclassical friction

Neoclassical physics (here associated to the poloidal variation of the magnetic field strength along field lines in a tokamak) is well known for driving self-generated plasma current and nonlinear magnetic islands associated to it in high performance, ITER relevant plasma discharges. It is demonstrated that the neoclassical friction between a magnetic perturbation and plasma flow already impacts magnetic islands in the linear regime, by inducing a weakening of curvature stabilization for tearing modes. This conclusion holds in particular for regimes where convection is influencing the pressure dynamics, as shown using a simple analytical model and confirmed in full Magneto-Hydro-Dynamics simulations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2014

Single-friction-surface triboelectric generator with human body conduit

We present a transparent single-friction-surface triboelectric generator (STEG) employing human body as the conduit, making the applications of STEG in portable electronics much more practical and leading to a significant output improvement. The STEG with micro-patterned polydimethylsiloxane surface achieved an output voltage of over 200 V with a current density of 4.7 μA/cm{sup 2}. With human body conduit, the output current increased by 39% and the amount of charge that transferred increased by 34% compared to the results with grounded electrode. A larger increment of 210% and 81% was obtained in the case of STEG with a large-size flat polyethylene terephthalate surface.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Measurement of local internal friction in metallic glasses

Atomic force acoustic microscopy (AFAM), an advanced scanning probe microscopy technique, has been used to measure local elastic properties with a spatial resolution given by the tip-sample contact radius. AFAM is based on inducing out-of-plane vibrations in the specimen. The vibrations are sensed by the AFM cantilever from by the photodiode signal when its tip is in contact with the material under test. To measure local damping, the inverse quality factor Q{sup −1} of the resonance curve is usually evaluated. Here, from the contact-resonance spectra obtained, we determine the real and imaginary part of the contact stiffness k* and from these two quantities the local damping factor Q{sub loc}{sup −1} is obtained which is proportional to the imaginary part γ of the contact stiffness. The evaluation of the data is based on the cantilever's mass distribution with damped flexural modes and not on an effective point-mass approximation for the cantilever’s motion. The given equation is simple to use and has been employed to study the local Q{sub loc}{sup −1} of amorphous PdCuSi metallic glass and its crystalline counterpart as a function of position of the AFM tip on the surface. The width of the distribution changes dramatically from the amorphous to the crystalline state as expected from the consequences of the potential-energy landscape picture. The center value of the distribution curve for Q{sub loc}{sup −1} coincides very well with published data, based on global ultrasonic or internal friction measurements. This is compared to Q{sub loc}{sup −1} measured in crystalline SrTiO{sub 3}, which exhibits a narrow distribution, as expected.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Eutectic structures in friction spot welding joint of aluminum alloy to copper

A dissimilar joint of AA5083 Al alloy and copper was produced by friction spot welding. The Al-MgCuAl{sub 2} eutectic in both coupled and divorced manners were found in the weld. At a relatively high temperature, mass transport of Cu due to plastic deformation, material flow, and atomic diffusion, combined with the alloy system of AA5083 are responsible for the ternary eutectic melting.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Controlling the number of graphene sheets exfoliated from graphite by designed normal loading and frictional motion

We use molecular dynamics to study the exfoliation of patterned nanometer-sized graphite under various normal loading conditions for friction-induced exfoliation. Using highly ordered pyrolytic graphite (HOPG) as well as both amorphous and crystalline SiO{sub 2} substrate as example systems, we show that the exfoliation process is attributed to the corrugation of the HOPG surface and the atomistic roughness of the substrate when they contact under normal loading. The critical normal strain, at which the exfoliation occurs, is higher on a crystalline substrate than on an amorphous substrate. This effect is related to the atomistic flatness and stiffness of the crystalline surface. We observe that an increase of the van der Waals interaction between the graphite and the substrate results in a decrease of the critical normal strain for exfoliation. We find that the magnitude of the normal strain can effectively control the number of exfoliated graphene layers. This mechanism suggests a promising approach of applying designed normal loading while sliding to pattern controlled number of graphene layers or other two-dimensional materials on a substrate surface.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Friction stir processing on carbon steel

Friction stir processing of medium carbon steel samples has been carried out using a milling machine and tools made of cemented tungsten carbide. Samples have been machined from 40 and 40X steels. The tools have been made in the shape of 5×5×1.5 mm and 3×3×1.5 mm tetrahedrons. The microstructure of stirred zone has been obtained using the smaller tool and consists of fine recrystallized 2-3 μm grains, whereas the larger tool has produced the 'onion-like' structures comprising hard quenched 'white' 500-600 MPa layers with 300-350 MPa interlayers of bainite needles. The mean values of wear intensity obtained after measuring the wear scar width were 0.02 mm/m and 0.001 mm/m for non-processed and processed samples, respectively.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Radiographic detection of defects in friction stir welding on aluminum alloy AMg5M

In order to reveal weld defects specific to friction stir welding we undertook radiographic inspection of AMg5M aluminum alloy welded joints. Weld defects in the form of voids have been revealed in the weld obtained under the non-optimal rotation and feed rate. Both shape and size of these defects have been confirmed by examining metallographically successive sections prepared in the weld plane as well as in the plane transversal to the tool feed direction. Linear defects have been also found in the sections that are not seen in the radiographic images. Both the preferable localization and origination of the defects have been analyzed.

36 MATERIALS SCIENCE↗
DOE OSTI2015

The microstructure of aluminum A5083 butt joint by friction stir welding

This study presents the microstructure of the aluminum A5083 butt joint surface after it has been joined by friction stir welding (FSW) process. The FSW process is a unique welding method because it will not change the chemical properties of the welded metals. In this study, MILKO 37 milling machine was modified to run FSW process on 4 mm plate of aluminum A5083 butt joint. For the experiment, variables of travel speed and tool rotational speed based on capability of machine were used to run FSW process. The concentrated heat from the tool to the aluminum plate changes the plate form from solid to plastic state. Two aluminum plates is merged to become one plate during plastic state and return to solid when concentrated heat is gradually further away. After that, the surface and cross section of the welded aluminum were investigated with a microscope by 400 x multiplication zoom. The welding defect in the FSW aluminum was identified. Then, the result was compared to the American Welding Society (AWS) FSW standard to decide whether the plate can be accepted or rejected.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2015

Structure and properties of fixed joints formed by ultrasonic-assisted friction-stir welding

This paper deals with structure and properties of aluminum alloy 7475 and its joints obtained by friction stir welding including under ultrasonic action. Microhardness measurements show that ultrasonic action increases strength properties of the joints. Optical and transmission electron microscopy reveals that this effect is related to the precipitation of tertiary coherent S-and T-phase particles.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Influence of tool shape on lattice rearrangement under loading conditions reproducing friction stir welding

Metal behavior under loading conditions that reproduce friction stir welding was studied on the atomic scale. Calculations were conducted based on molecular dynamics simulation with potentials calculated within the embedded atom method. The loading of the interface between two crystallites, whose structure corresponded to aluminum alloy 2024, was simulated by the motion of a cone-shaped tool along the interface with constant angular and translational velocities. The motion of the rotating tool causes fracture of the workpiece crystal structure with subsequent mixing of surface atoms of the interfacing crystallites. It is shown that the resistance force acting on the moving tool from the workpiece and the process of structural defect formation in the workpiece depend on the tool shape.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Influence of vibrational treatment on thermomechanical response of material under conditions identical to friction stir welding

A molecular dynamics model was constructed to describe material loading on the atomic scale by the mode identical to friction stir welding. It was shown that additional vibration applied to the tool during the loading mode provides specified intensity values and continuous thermomechanical action during welding. An increase in additional vibration intensity causes an increase both in the force acting on the workpiece from the rotating tool and in temperature within the welded area.

42 ENGINEERING↗
DOE OSTI2015

Friction stir processing on high carbon steel U12

Friction stir processing (FSP) of high carbon steel (U12) samples has been carried out using a milling machine and tools made of cemented tungsten carbide. The FSP tool has been made in the shape of 5×5×1.5 mm. The microstructural characterization of obtained stir zone and heat affected zone has been carried out. Microhardness at the level of 700 MPa has been obtained in the stir zone with microstructure consisting of large grains and cementitte network. This high-level of microhardness is explained by bainitic reaction developing from decarburization of austenitic grains during cementite network formation.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Wettability and friction of water on a MoS{sub 2} nanosheet

The molybdenum disulfide (MoS{sub 2}) nanosheet is a promising two-dimensional (2D) material and has recently been used in biological sensing. While the electronic structure of 2D MoS{sub 2} sheet has been actively studied, the role of its atomic structure and thus the interfacial interactions with bio-fluids are still elusive. Using Molecular dynamics simulations, we developed MoS{sub 2} force field parameters to reproduce the experimentally determined water contact angle of the MoS{sub 2} nanosheet and then predicted the slip-length of water that has not been measured in experiment yet. Simulation results suggest that the MoS{sub 2} nanosheet is a hydrophobic and low-friction surface, despite its seemingly significant charges of surface atoms and relatively strong strength of van der Waals potentials. We expect that the developed force fields for depicting surface atoms of MoS{sub 2} will facilitate future research in understanding biomolecule-MoS{sub 2} interactions in MoS{sub 2}-based biosensors.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗