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125 records · Page 7

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Welding of Haynes 282 to Steels to Enable Modular Rotors for Advanced Ultra Super-Critical Steam Turbines

Steam turbines for an Advanced Ultra Super Critical (AUSC) fossil fired power plant will operate at temperatures well above those of current commercial steam cycles with inlet temperatures more than 760 C , which is beyond the capabilities of alloy steels presently used for steam turbine applications and requires advanced materials. Large components such as steam turbine rotors may be made of nickel based super alloys such as Haynes 282 (H282). However, monolithic forgings of superalloys in the sizes required for large steam turbines rotors can be prohibitively expensive besides many technical challenges. To minimize cost and alleviate the related technical challenges, superalloy use needs to be limited to locations on the steam turbine rotor where strength and temperature requirements cannot be met by conventional steels. This is possible if nickel-based superalloys can be successfully welded to steels and the related technical challenges - machining parts made of dissimilar welded materials, non-destructive examination of such welds for flaw detection; and, material properties of such hybrid components – are sufficiently addressed. In this technology development project, we successfully welded H282 to plates up to ~ 75 mm (~ 3 inches) to a 3.5NiCrMoV steel of similar thickness. Advanced ultrasonic inspection technique called Phased Array Ultrasonic Testing (PAUT) was employed to examine the dissimilar H282-Steel welds, into which flat bottomed side drilled holes (SDH) of various diameters were introduced, to determine the minimum detectable feature sizes; it was shown that with PAUT SDH of dia. down to 0.5 mm could be detected in the base alloys and SDH with dia. down to 2.4 mm could be detected in the weld metal under multiple orientations successfully. An autonomous machining process monitoring system was developed and demonstrated whereby the forces acting on the cutting tool could be actively monitored as the cutting tool transitioned from H282 to Steel across the weld using which the machining parameters can be potentially altered without interruption to extend tool life. This project successfully achieved its objectives of - i. Developing a welding methodology and viable welding geometries, to successfully join H282 to steel 3.5CrMoNiV steel to enable manufacture of modular steam turbine rotors for AUSC applications (conditions of at least 760 °Celsius and 3,100 psia (pounds per square inch absolute pressure) and evaluate the material properties of the welded specimen. ii. Employ the advanced ultrasonic inspection technique to the dissimilar weld metal joint and determine the minimum detectable feature sizes. iii. Develop effective machining techniques to machine such hybrid structures with online tool force monitoring and effect machine state metrics for optimal results.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1972

Diffusion bonding of IN 718 to VM 350 grade maraging steel

Diffusion bonding studies have been conducted on IN 718, VM 350 and the dissimilar alloy couple, IN 718 to maraging steel. The experimental processing parameters critical to obtaining consistently good diffusion bonds between IN 718 and VM 350 were determined. Interrelationships between temperature, pressure and surface preparation were explored for short bending intervals under vacuum conditions. Successful joining was achieved for a range of bonding cycle temperatures, pressures and surface preparations. The strength of the weaker parent material was used as a criterion for a successful tensile test of the heat treated bond. Studies of VM-350/VM-350 couples in the as-bonded condition showed a greater yielding and failure outside the bond region.

Crosby, S. R.↗

NASA NTRS1994

Metafusion: A breakthrough in metallurgy

The Metafuse Process is a patented development in the field of thin film coatings utilizing cold fusion which results in a true inter-dispersion of dissimilar materials along a gradual transition gradient through a boundary of several hundred atomic layers. The process is performed at ambient temperatures and pressures requiring relatively little energy and creating little or no heat. The process permits a remarkable range of material combinations and joining of materials which are normally incompatible. Initial applications include titanium carbide into and onto the copper resistance welding electrodes and tungsten carbide onto the cutting edges of tool steel blades. The process is achieved through application of an RF signal of low power and is based on the theory of vacancy fusion.

Joseph, Adrian A.↗

DOE OSTI2023

Plasma treatment on both adhesive tape and adherends for significantly enhanced CFRTP-related adhesive joints

Unlike existing literature that primarily concentrates on either the plasma treatment of adherends alone or solely on adhesive surfaces, this work leverages plasma modification of both adhesive in tape form and adherend surfaces to largely enhance the interfacial bonding between a thermoset-based adhesive tape and carbon-fiber-reinforced thermoplastic polymer (CFRTP) for structural bonding applications. Here, by conducting single lap shear tests on adhesively-bonded AA6061-CFRPPA (carbon-fiber-reinforced polyphthalamide) dissimilar joints, it is shown that the plasma treatment of adherends alone can increase the lap shear strength (LSS) of the joints by approximately 200% compared to non-treated counterparts. An additional plasma treatment of adhesive tape surfaces leads to even higher LSS improvement, reaching up to 315%, due to the formation of a denser crosslinked network of covalent bonds and a reduced area fraction of interfacial voids at the CFRPPA/adhesive interface. The highest plasma-enhanced LSS of the metal-CFRTP dissimilar joints rivals that of metal-metal joints, which is typically stronger than the joints associated with fiber-reinforced polymers. This study is important for achieving strong CFRTP-related structural components bonded using adhesive tape, providing better compatibility with plasma treatment and other joining methods like riveting compared to adhesive paste or liquid.

36 MATERIALS SCIENCE↗

NASA NTRS2013

Integration Science and Technology of Silicon-Based Ceramics and Composites:Technical Challenges and Opportunities

Ceramic integration technologies enable hierarchical design and manufacturing of intricate ceramic and composite parts starting with geometrically simpler units that are subsequently joined to themselves and/or to metals to create components with progressively higher levels of complexity and functionality. However, for the development of robust and reliable integrated systems with optimum performance for high temperature applications, detailed understanding of various thermochemical and thermomechanical factors is critical. Different technical approaches are required for the integration of ceramic to ceramic and ceramic to metal systems. Active metal brazing, in particular, is a simple and cost-effective method to integrate ceramic to metallic components. Active braze alloys usually contain a reactive filler metal (e.g., Ti, Cr, V, Hf etc) that promotes wettability and spreading by inducing chemical reactions with the ceramics and composites. In this presentation, various examples of brazing of silicon nitride to themselves and to metallic systems are presented. Other examples of joining of ceramic composites (C/SiC and SiC/SiC) using ceramic interlayers and the resulting microstructures are also presented. Thermomechanical characterization of joints is presented for both types of systems. In addition, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be presented.

Singh, M.↗

NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗

DOE OSTI2020

Joining of Thermoset Carbon Fiber Reinforced Polymer and AZ31 Magnesium Alloy Sheet Via Friction Stir Interlocking

A new technique called friction stir interlocking (FSI) was applied for lap-joining of AZ31 magnesium sheet and thermoset carbon fiber reinforced polymer (TS-CFRP) sheet. Instead of directly joining AZ31 and TS-CFRP, a series of magnesium interlocks were used to friction stir weld with AZ31 sheet to enable joining with TS-CFRP. Microstructural characterization of joint cross sections showed that a tool rotation rate of 800 rpm produced incomplete mixing of magnesium interlocks and the top AZ31 sheet, while 1200 rpm achieved sufficient material mixing to avoid unwelded regions. Mechanical property characterization showed that AZ31/TS-CFRP dissimilar joints failed through the magnesium interlock shanks during lap shear tensile testing, with a maximum normalized joint strength reaching ~100 MPa.

Wang, Tianhao↗

DOE OSTI2021

Mitigation of Galvanic Corrosion in Bolted Joint of AZ31B and Carbon Fiber-Reinforced Composite Using Polymer Insulation

The use of polymer insulation to mitigate galvanic corrosion was examined for bolted joints of AZ31B Mg alloy and carbon fiber-reinforced composite. To assess the corrosion behaviors of bolted joints with and without polymer insulation, solution immersion and salt spray exposure (ASTM B117) tests were conducted, and the corrosion depths and volumes were determined for the joint specimens after the tests. The polymer-insulated bolted joints exhibited much lower corrosion depths and volumes, highlighting the effective mitigation of galvanic corrosion. The reductions of joint strength in the post-corrosion joint specimens were relatively small (up to ~10%) in the polymer-insulated group but greater (up to 90%) in the group with no insulation. Cross-sectional characterization of post-corrosion joints with polymer insulation revealed local pits developed on AZ31B under galvanic influence, indicating that limited galvanic attack (that did not decrease the joining integrity significantly) could still occur during a long salt spray exposure (~1264 h) owing to the permeation of an aqueous corrosive medium.

36 MATERIALS SCIENCE↗

NASA NTRS2007

Ceramic Integration Technologies for Aerospace and Energy Systems: Technical Challenges and Opportunities

Ceramic integration technology has been recognized as an enabling technology for the implementation of advanced ceramic systems in a number of high-temperature applications in aerospace, power generation, nuclear, chemical, and electronic industries. Various ceramic integration technologies (joining, brazing, attachments, repair, etc.) play a role in fabrication and manufacturing of large and complex shaped parts of various functionalities. However, the development of robust and reliable integrated systems with optimum performance requires the understanding of many thermochemical and thermomechanical factors, particularly for high temperature applications. In this presentation, various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Experimental results for bonding and integration of SiC based LDI fuel injector, high conductivity C/C composite based heat rejection system, solid oxide fuel cells system, ultra high temperature ceramics for leading edges, and ceramic composites for thermostructural applications will be presented. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be discussed.

Singh, Mrityunjay↗

DOE OSTI2021

Process Robustness of Friction Stir Dovetailing of AA7099 to Steel with In Situ AA6061 Interlayer Linking

Rolled homogeneous armor (RHA) steel was joined to aluminum alloy AA7099-T7451 with an interlayer of AA6061-T651 by single-pass friction stir dovetailing (FSD). The evolution of the AA7099/AA6061 and AA6061/steel interfacial microstructures and mechanical properties of the joints were examined. The AA6061 interlayer prevented Zn migration from the AA7099 to the steel during FSD and inhibited formation of brittle, Zn-rich, Fe-Al intermetallic compounds within the joint. The flow of the dissimilar aluminum alloys at the interface was controlled with a partially threaded friction stir welding pin and a dovetail geometric configuration optimized in previous work. The process robustness was explored to establish parameter windows by elucidating parametric effects on the relationship between process conditions and the joint’s microstructure and mechanical properties. Ranges of process forge force (50–70 kN) and interface temperature (475°C–515°C) consistently yielded joints with adequate performance. The load-carrying capacity in lap shear tensile tests was 2025 ? 100 N/mm.

Friction Stir Dovetailing, FSW, AA7099, AA6061, Ro↗

NASA NTRS2012

A Compendium of Brazed Microstructures For Fission Power Systems Applications

NASA has been supporting design studies and technology development for fission-based power systems that could provide power to an outpost on the Moon, Mars, or an asteroid. Technology development efforts have included fabrication and evaluation of components used in a Stirling engine power conversion system. This investigation is part of the development of several braze joints crucial for the heat exchanger transfer path from a hot-side heat exchanger to a Stirling engine heat acceptor. Dissimilar metal joints are required to impart both mechanical strength and thermal path integrity for a heater head of interest. Preliminary design work for the heat exchanger involved joints between low carbon stainless steel to Inconel 718, where the 316L stainless steel would contain flowing liquid metal NaK while Inconel 718, a stronger alloy, would be used as structural reinforcement. This paper addressed the long-term microstructural stability of various braze alloys used to join 316L stainless steel heater head to the high conductivity oxygen-free copper acceptor to ensure the endurance of the critical metallic components of this sophisticated heat exchanger. The bonding of the 316L stainless steel heater head material to a copper heat acceptor is required to increase the heat-transfer surface area in contact with flowing He, which is the Stirling engine working fluid.

Locci, Ivan E.↗

NASA NTRS1985

Advanced fabrication techniques for hydrogen-cooled engine structures

Described is a program for development of coolant passage geometries, material systems, and joining processes that will produce long-life hydrogen-cooled structures for scramjet applications. Tests were performed to establish basic material properties, and samples constructed and evaluated to substantiate fabrication processes and inspection techniques. Results of the study show that the basic goal of increasing the life of hydrogen-cooled structures two orders of magnitude relative to that of the Hypersonic Research Engine can be reached with available means. Estimated life is 19000 cycles for the channels and 16000 cycles for pin-fin coolant passage configurations using Nickel 201. Additional research is required to establish the fatigue characteristics of dissimilar-metal coolant passages (Nickel 201/Inconel 718) and to investigate the embrittling effects of the hydrogen coolant.

Buchmann, O. A.↗

NASA NTRS2012

Integration Science and Technology of Advanced Ceramics for Energy and Environmental Applications

The discovery of new and innovative materials has been known to culminate in major turning points in human history. The transformative impact and functional manifestation of new materials have been demonstrated in every historical era by their integration into new products, systems, assemblies, and devices. In modern times, the integration of new materials into usable products has a special relevance for the technological development and economic competitiveness of industrial societies. Advanced ceramic technologies dramatically impact the energy and environmental landscape due to potential wide scale applications in all aspects of energy production, storage, distribution, conservation, and efficiency. Examples include gas turbine propulsion systems, fuel cells, thermoelectrics, photovoltaics, distribution and transmission systems based on superconductors, nuclear power generation, and waste disposal. Robust ceramic integration technologies enable hierarchical design and manufacturing of intricate ceramic components starting with geometrically simpler units that are subsequently joined to themselves and/or to metals to create components with progressively higher levels of complexity and functionality. However, for the development of robust and reliable integrated systems with optimum performance under different operating conditions, the detailed understanding of various thermochemical and thermomechanical factors is critical. Different approaches are required for the integration of ceramic-metal and ceramic-ceramic systems across length scales (macro to nano). In this presentation, a few examples of integration of ceramic to metals and ceramic to ceramic systems will be presented. Various challenges and opportunities in design, fabrication, and testing of integrated similar (ceramic-ceramic) and dissimilar (ceramic-metal) material systems will be discussed. Potential opportunities and need for the development of innovative design philosophies, approaches, and integrated system testing under simulated application conditions will also be presented.

Singh, M.↗

NASA NTRS2008

XTCE and XML Database Evolution and Lessons from JWST, LandSat, and Constellation

The database organizations within three different NASA projects have advanced current practices by creating database synergy between the various spacecraft life cycle stakeholders and educating users in the benefits of the Consultative Committee for Space Data Systems (CCSDS) XML Telemetry and Command Exchange (XTCE) format. The combination of XML for managing program data and CCSDS XTCE for exchange is a robust approach that will meet all user requirements using Standards and Non proprietary tools. COTS tools for XTCEKML are very wide and varied. To combine together various low cost and free tools can be more expensive in the long run than choosing a more expensive COTS tool that meets all the needs. This was especially important when deploying in 32 remote sites with no need for licenses. A common mission XTCEKML format between dissimilar systems is possible and is not difficult. Command XMLKTCE is more complex than telemetry and the use of XTCEKML metadata to describe pages and scripts is needed due to the proprietary nature of most current ground systems. Other mission and science products such as spacecraft loads, science image catalogs, and mission operation procedures can all be described with XML as well to increase there flexibility as systems evolve and change. Figure 10 is an example of a spacecraft table load. The word is out and the XTCE community is growing, The f ~ sXt TCE user group was held in October and in addition to ESAESOC, SC02000, and CNES identified several systems based on XTCE. The second XTCE user group is scheduled for March 10, 2008 with LDMC and others joining. As the experience with XTCE grows and the user community receives the promised benefits of using XTCE and XML the interest is growing fast.

Gal-Edd, Jonathan↗

NASA NTRS1972

Friction welding.

Results of an exploratory study of the structure and properties of friction welds in Udimet 700 (U-700) and TD-nickel (TD-Ni) bar materials, as well as dissimilar U-700/TD-Ni friction welds. Butt welds were prepared by friction welding 12.7-mm-diam U-700 bars and TD-Ni bars. Specimens for elevated temperature tensile and stress rupture testing were machined after a postweld heat treatment. Friction welding of U-700 shows great potential because the welds were found to be as strong as the parent metal in stress rupture and tensile tests at 760 and 980 C. In addition, the weld line was not detectable by metallographic examination after postheating. Friction welds in TD-Ni or between U-700 and TD-Ni were extremely weak at elevated temperatures. The TD-Ni friction welds could support only 9% as much stress as the base metal for 10-hour stress rupture life at 1090 C. The U-700/TD-Ni weld could sustain only 15% as much stress as the TD-Ni parent metal for a 10-hour stress rupture life at 930 C. Thus friction welding is not a suitable joining method for obtaining high-strength TD-Ni or U-700/TD-Ni weldments.

Moore, T. J.↗

NASA NTRS2010

Advanced Flip Chips in Extreme Temperature Environments

The use of underfill materials is necessary with flip-chip interconnect technology to redistribute stresses due to mismatching coefficients of thermal expansion (CTEs) between dissimilar materials in the overall assembly. Underfills are formulated using organic polymers and possibly inorganic filler materials. There are a few ways to apply the underfills with flip-chip technology. Traditional capillary-flow underfill materials now possess high flow speed and reduced time to cure, but they still require additional processing steps beyond the typical surface-mount technology (SMT) assembly process. Studies were conducted using underfills in a temperature range of -190 to 85 C, which resulted in an increase of reliability by one to two orders of magnitude. Thermal shock of the flip-chip test articles was designed to induce failures at the interconnect sites (-40 to 100 C). The study on the reliability of flip chips using underfills in the extreme temperature region is of significant value for space applications. This technology is considered as an enabling technology for future space missions. Flip-chip interconnect technology is an advanced electrical interconnection approach where the silicon die or chip is electrically connected, face down, to the substrate by reflowing solder bumps on area-array metallized terminals on the die to matching footprints of solder-wettable pads on the chosen substrate. This advanced flip-chip interconnect technology will significantly improve the performance of high-speed systems, productivity enhancement over manual wire bonding, self-alignment during die joining, low lead inductances, and reduced need for attachment of precious metals. The use of commercially developed no-flow fluxing underfills provides a means of reducing the processing steps employed in the traditional capillary flow methods to enhance SMT compatibility. Reliability of flip chips may be significantly increased by matching/tailoring the CTEs of the substrate material and the silicon die or chip, and also the underfill materials. Advanced packaging interconnects technology such as flip-chip interconnect test boards have been subjected to various extreme temperature ranges that cover military specifications and extreme Mars and asteroid environments. The eventual goal of each process step and the entire process is to produce components with 100 percent interconnect and satisfy the reliability requirements. Underfill materials, in general, may possibly meet demanding end use requirements such as low warpage, low stress, fine pitch, high reliability, and high adhesion.

Ramesham, Rajeshuni↗

DOE OSTI2025

Multiple‐Repeated Plasma Surface Treatments for Significantly Improving Bonding Performance of Metal‐Carbon‐Fiber‐Reinforced Thermoplastic Polymer Dissimilar Adhesive Joints

This work investigates how multiple‐repeated plasma surface treatments can significantly enhance adhesively bonded metal‐carbon‐fiber‐reinforced thermoplastic polymer (CFRTP) dissimilar joints, a topic that has been rarely investigated compared to other parameters during the plasma treatment process. By conducting double cantilever beam tests on adhesively bonded AA6061‐carbon‐fiber‐reinforced polyphthalamide (CFRPPA) dissimilar joints, it is shown that the average Mode I specific fracture energy after 20 repetitions of the same plasma treatment, using processing parameters without noticeably changing surface roughness, can be improved and saturated up to almost 2000% compared to non‐treated joints and almost 240% compared to a single plasma treatment commonly used in the literature. The improvement can be attributed to the enhanced chemical bonding at the CFRPPA‐adhesive interface. This study is important for achieving strong bonding performance of CFRTP‐related structural joints using multiple plasma treatments, a simple and effective method.

36 MATERIALS SCIENCE↗