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At least 127 records · Page 7

NBL Pistol Grip Tool for Underwater Training of Astronauts

A document discusses a lightweight, functional mockup of the Pistol Grip Tool for use during underwater astronaut training. Previous training tools have caused shoulder injuries. This new version is more than 50 percent lighter [in water, weight is 2.4 lb (=1.1 kg)], and can operate for a six-hour training session after 30 minutes of prep for submersion. Innovations in the design include the use of lightweight materials (aluminum and Delrin(Registered TradeMark)), creating a thinner housing, and the optimization of internal space with the removal of as much excess material as possible. This reduces tool weight and maximizes buoyancy. Another innovation for this tool is the application of a vacuum that seats the Orings in place and has shown to be reliable in allowing underwater usage for up to six hours.

Liszka, Michael↗

A new diagnostic method for separating airborne and structureborne noise radiated by plates with applications for propeller driven aircraft

The anticipated application of advanced turboprop propulsion systems is expected to increase the interior noise of future aircraft to unacceptably high levels. The absence of technically and economically feasible noise source-path diagnostic tools has been a prime obstacle in the development of efficient noise control treatments for propeller-driven aircraft. A new diagnostic method that permits the separation and prediction of the fully coherent airborne and structureborne components of the sound radiated by plates or thin shells has been developed. Analytical and experimental studies of the proposed method were performed on an aluminum plate. The results of the study indicate that the proposed method could be used in flight, and has fewer encumbrances than the other diagnostic tools currently available.

Mcgary, Michael C.↗

Optimizing chemistry for designing oxidation resistant FeCrAl alloys

Abstract Traditionally, FeCrAl alloys played an important role in high-temperature applications due to their ability to form a passive Al oxide film at temperatures above ~ 800 °C. Recently, FeCrAl alloys became of interest for the application of accident tolerant nuclear fuel cladding. This study covers work done at GE Research for better understanding the role of Al, Cr, and Mo in oxidation kinetics and thermodynamics. Several models and commercial prototype alloys have been tested in hydrothermal corrosion autoclave loops, at low temperature steam exposure (~ 400 °C), high temperature steam exposure (~ 1000 °C or higher), and high temperature air exposures. The results provide insights on how chromium and aluminum play a significant role in both high temperature and low temperature oxidation of FeCrAl. Additionally, machine learning tools are used to gain further insights on both predicting future optimized chemistries for balancing the properties of hydrothermal corrosion, low and high temperature steam oxidation, and thermal aging (which is exacerbated due to radiation in a nuclear reactor environment). GE plans to use this framework to further optimize the FeCrAl alloy system for use in nuclear reactor environments. Graphical abstract

Roy, Indranil (ORCID:0000000336124323)↗

Low cost tooling material and process for graphite and Kevlar composites

An Extruded Sheet Tooling Compound (ESTC) was developed for use in quickly building low cost molds for fabricating composites. The ESTC is a very highly mineral-filled resin system formed into a 6 mm thick sheet. The sheet is laid on the pattern, vacuum (bag) is applied to remove air from the pattern surface, and the assembly is heat cured. The formed ESTC is then backed and/or framed and ready for use. The cured ESTC exhibits low coefficient of thermal expansion and maintains strength at temperatures of 180 to 200 C. Tools were made and used successfully for: Compression molding of high strength epoxy sheet molding compound, stamping of aluminum, resin transfer molding of polyester, and liquid resin molding of polyester. Several variations of ESTC can be made for specific requirements. Higher thermal conductivity can be achieved by using an aluminum particle filler. Room temperature gel is possible to allow use of foam patterns.

Childs, William I.↗

Numerical Simulation and Experimental Validation of Joint Performance in Aluminum-Steel Lap Welds Formed by Friction Stir Dovetailing

Friction stir dovetailing (FSD) is a new dissimilar material joining process that simultaneously forms a mechanical interlock and metallurgical bond at the dissimilar material interface. This work presents development of a modeling and simulation approach to predict mechanical performance of FSD thick section aluminum to steel joints. A finite element analysis (FEA) was carried out in order to predict the load-carrying capacity and failure location for aluminum thicknesses between 12.7 mm and 50.8 mm with different numbers of dovetails. The numerical results and corresponding experimental investigation are in agreement and suggest that the developed methods can be used effectively for design and analysis of FSD joints using standard FEA tools.

Friction stir dovetailing, Friction stir welding, ↗

Friction stir welding process to repair voids in aluminum alloys

The present invention provides an in-process method to repair voids in an aluminum alloy, particularly a friction stir weld in an aluminum alloy. For repairing a circular void or an in-process exit hole in a weld, the method includes the steps of fabricating filler material of the same composition or compatible with the parent material into a plug form to be fitted into the void, positioning the plug in the void, and friction stir welding over and through the plug. For repairing a longitudinal void (30), the method includes machining the void area to provide a trough (34) that subsumes the void, fabricating filler metal into a strip form (36) to be fitted into the trough, positioning the strip in the trough, and rewelding the void area by traversing a friction stir welding tool longitudinally through the strip. The method is also applicable for repairing welds made by a fusing welding process or voids in aluminum alloy workpieces themselves.

Rosen, Charles D.↗

Effect of tool design and pass strategy on defect elimination and uniform, enhanced tensile properties of friction stir processed high-pressure die-cast A380 alloy

This work reports implementation of friction stir processing (FSP) to locally modify microstructure and create a defect-free processing zone with the aid of different tool designs and altering the passing strategy for two different process parameter combinations. Here, FSP is applied on high pressure die-cast (HPDC) A380 alloy, a widely used Al-Si alloy fabricated in the die casting sector for automotive and aerospace applications. However, the presence of gas and shrinkage porosity, brittle needle-shaped Fe-containing ß-FeSiAl 5 intermetallic compounds, Al-dendrites, coarse and acicular silicon particles, and large second-phase particulates have a detrimental influence on the uniformity of tensile properties across the thickness direction of an HPDC plate. FSP is able to eliminate porosity, refine microstructure and improve tensile properties. An FSP tool design and a passing strategy are identified for the best microstructure consolidation and uniform enhanced tensile properties. This study noted the importance of tool features such as scroll design and flats on tool pin and multiple pass orientation strategy to find best combination of defect-free refined microstructure and uniform tensile strength and ductility across the processing zone of HPDC Al alloys.

36 MATERIALS SCIENCE↗

Portable Pipe Wrapper

New tool applies fragile layered insulation to cryogenic tubing. Used routinely to apply two layers of fiberglass and one of aluminum foil on pipe used as inner line in vacuum jacketed cryogenic plumbing. Wrapper is easy to use and made from inexpensive, readily available parts. Wheeled to whatever location is convenient for wrapping.

Dennis, G. B.↗

A Versatile Simulation Framework for Elastodynamic Modeling of Structural Health Monitoring

Structural health monitoring (SHM) has the capacity to reduce failure by detecting damage during service life, by periodic, automated monitoring. Guided Wave (GW) Ultrasound is a common SHM approach for aerospace structures. Modelling the physics of GW SHM systems provides a route for understanding system dependencies, capabilities and limitations as damage evolves during service life. Such a toolset can strengthen the understanding of the connection between GW SHM results and the true material state. The most useful modelling tools are those that provide versatile solutions with respect to the simulated component geometry and computational grid connectivity. This work details a versatile application programming interface (API) for the elastodynamic finite integration technique for modelling GW SHM of metals. The custom code implementation, EFIT-CompCell, allows for the modelling of diverse geometries by automatically balancing the message passing interface parallelization layout. The user provides the basic parameters of the simulation and the software automatically performs an initial balancing based on anticipated computational loads, and establishes the CPU communication patterns for any geometry. This work describes the programming philosophy and code structure used to create EFIT-CompCell and compares its performance and capacity to simulation tools that are more specialized for specific architectures. Results are presented for a simulation of GW SHM of an aluminum fuselage section being tested by the FAA. The simulation consists of 733M voxels which took approximately 70 hours to complete 25000 time steps using 40 Intel Xeon E5-4650v2 Ivy Bridge processor cores.

Gregory, Elizabeth D.↗

Manufacturing of magnesium/aluminum bimetallic ring components by friction stir assisted simultaneous forging and solid-state joining

Here, a bimetallic ring component is forged by a friction stir assisted forging (FS-forging). A cylindrical bimetallic blank, magnesium AZ31 cylinder (Mg core) tightly fitted inside an aluminum 6061-T6 tube (Al skin), is used. In the FS-forging, the frictional heat and stirring of rotating tool forge the blank into a desired shape, while simultaneously generate a solid-state joint between the Mg core and the Al skin, without additional external heating, as confirmed by the microstructural analysis and mechanical tests. The microstructural analysis also shows that the characteristics of the solid-state joint can be different depending on the process parameters.

42 ENGINEERING↗

Thermoelectric current in a graphene Cooper pair splitter

Generation of electric voltage in a conductor by applying a temperature gradient is a fundamental phenomenon called the Seebeck effect. This effect and its inverse is widely exploited in diverse applications ranging from thermoelectric power generators to temperature sensing. Recently, a possibility of thermoelectricity arising from the interplay of the non-local Cooper pair splitting and the elastic co-tunneling in the hybrid normal metal-superconductor-normal metal structures was predicted. Here, we report the observation of the non-local Seebeck effect in a graphene-based Cooper pair splitting device comprising two quantum dots connected to an aluminum superconductor and present a theoretical description of this phenomenon. The observed non-local Seebeck effect offers an efficient tool for producing entangled electrons.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

New concept in brazing metallic honeycomb panels

Aluminum oxide coating provides surface which will not be wetted by brazing alloy and which stops metallic diffusion welding of tooling materials to part being produced. This method eliminates loss of tooling materials and parts from braze wetting and allows fall-apart disassembly of tooling after brazing.

Carter, P. D.↗

Eutectic bonding of boron-aluminum structural components. II

Eutectic bonding is a diffusion brazing process developed for fabricating boron-aluminum components from composite monolayer. This process relies on the diffusion of a thin surface film of copper into the aluminum matrix to form a liquid phase when heated above the copper-aluminum eutectic temperature of 1018 F. This type of fabrication offers design flexibility in that skin thickness may be varied, the stiffness geometry and orientation can be varied, and local reinforcement can be added. In addition, this type of boron-aluminum structure offers high efficiency. Also, this method of construction can be cost-comparative with complex titanium shapes; simple tooling permits easy layup, bonding is a one-step operation, and little finish machining is required.

Niemann, J. T.↗

Technology of welding aluminum alloys-III

Control of porosity in weld beads was major objective in development of aluminum welding program. Porosity, most difficult defect to control, is caused by hydrogen gas unable to escape during solidification. Hard tooling allows hotter bead than free-fall tooling so hydrogen bubbles can boil out instead of forming pores. Welding position, moisture, and cleanliness are other important factors in control of porosity.

Harrison, J. R.↗

Celion/Larc-160 graphite/polyimide composite processing techniques and properties

Weight savings in the range from 25 to 35 percent could be achieved on Space Shuttle orbiter components and the thermal protection system (TPS) by employing a suitable graphite/polyimide (Gr/Pi) composite material system as a substitute for the baseline aluminum structural material. Predicted weight savings are based on the superior strength and stiffness-to-density ratios of Gr/Pi composite material over metallic counterparts. Specific strength and stiffness properties of Celion/Larc-160 composite laminates are compared with aluminum and titanium alloys. Aspects of materials and processes development are discussed, taking into account Celion/Larc-160 composite cure cycle and tooling evolution, complex shaped component process development, mechanical and physical properties testing and results, and structural element design fabrication, testing, and results. Attention is given to a demonstration of materials and processing technology, and a Celion/Larc-160 materials and processes summary is presented.

Jones, J. S.↗

The Plunge Phase of Friction Stir Welding

Torque and plunge force during the initial plunge phase in Friction Stir Welding were measured for a 0.5 inch diameter pin entering a 2219 aluminum alloy plate. Weld structures were preserved for metallographic observation by making emergency stops at various plunge depths. The plunging pin tool is seen to be surrounded by a very fine grained layer of recrystallized metal extending substantially below the bottom of the pin, implying a shear interface in the metal below and not at the tool-metal interface. Torque and plunge force during the initial plunge phase in Friction Stir Welding are calculated from a straight forward model based on a concept to plastic flow in the vicinity of the plunging tool compatible with structural observations. The concept: a disk of weld metal seized to and rotating with the bottom of the pin is squeezed out laterally by the plunge force and extruded upwards in a hollow cylinder around the tool. As the shear surface separating rotating disk from stationary weld metal engulfs fresh metal, the fresh metal is subjected to severe shear deformation, which results in its recrystallization. Encouraging agreement between computations and measured torque and plunge force is obtained.

Nunes, Arthur↗

Assessment of small mechanical wastewater treatment plants: Relative life cycle environmental impacts of construction and operations

Many slow growing and shrinking rural communities struggle with aging or inadequate wastewater treatment plants (WWTPs), and face challenges in constructing and operating such facilities. Although existing literature has provided insight into the environmental sustainability of large facilities, including both the construction and operational phases, these studies have not examined small, rural facilities treating less than 7,000 m 3 /d (1.8 MGD) of wastewater in adequate depth and breadth. In this study, a detailed inventory of the construction and operational data for 16 case studies of small WWTPs was developed to elucidate their environmental life cycle impacts. Conventional LCA framework was followed. The results show that the environmental impacts of both the construction and operational phases are considerable. Operational impacts are highly related to energy usage. Improving energy efficiency of a plant may reduce the environmental impacts related to operations. Construction impacts can vary considerably between facilities. Process-related factors (e.g., concrete and reinforcing steel used in basins) are typically sized using the design flow; thus much of the variability in construction impacts among plants stems from the non-process related infrastructure. Multiple regression analysis was used as an exploratory tool to identify which non-process related plant aspects contribute to the variable environmental impact of small WWTPs. These factors include aluminum, cast iron, and the capacity utilization ratio (defined as the ratio of average flow to design flow). Furthermore, industry practitioners should consider these factors when aiming to reduce the environmental impacts of a small WWTP related to construction. Scenario sensitivity analyses found that the environmental impact of construction became smaller with longer design life, and the end-of-life consideration does not heavily influence the environmental sustainability of a WWTP.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

FLUKA simulation validation to measure the beam energy of a cyclotron

FLUKA is a fully integrated particle physics MonteCarlo simulation package which has many applications in high energy experimental physics and engineering. When using a cyclotron for medical radionuclide production, it is important to know that the beam energy is suitable to cause the intended nuclear reaction and minimize unwanted impurities. Here, this work focuses on the comparison of FLUKA as a tool to measure the beam energy of a cyclotron with experimental results using the method of stacked copper foils interspaced by an aluminum degrader. We compared two methods to determine the activity ratio: determining the activity in each foil using the experimentally measured cross-sections from the National Nuclear Data Center (NNDC) cross-section data and calculating the activity in the two Cu foils using the FLUKA program. These results were compared to those reported by Gagnon et al., 2011. The FLUKA results gave energy measurements that were different than the true energy by a percentage in the range of 2.4% to 13%, suggesting that FLUKA is not recommended for pre-calculating the cyclotron beam energy using these low Z materials without experimental confirmation. It also confirms that the experimental cross-section data from the NNDC database is superior for this application giving energy values that ranged from 0.1% to 1.6% from the true energy.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗