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At least 1,369 records · Page 76
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

In-situ study of rules of nanostructure evolution, severe plastic deformations, and friction under high pressure

Severe plastic deformations under high pressure are used to produce nanostructured materials but were studied ex-situ. Rough diamond anvils are introduced to reach maximum friction equal to yield strength in shear and the first in-situ study of the evolution of the pressure-dependent yield strength and radial distribution of nanostructural parameters are performed for severely pre-deformed Zr. ω-Zr behaves like perfectly plastic, isotropic, and strain-path-independent and reaches steady values of the crystallite size and dislocation density, which are pressure-, strain- and strain-path-independent. However, steady states for a-Zr obtained with smooth and rough anvils are different, causing major challenge in plasticity theory. In-situ study of severe plastic deformation of α-Zr with rough diamond anvils revealed that pressure-dependent yield strength, crystallite size, and dislocation density are getting steady and plastic strain- and strain-path-independent.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Application of gas dynamical friction for planetesimals. I. Evolution of single planetesimals

The growth of small planetesimals into large planetary embryos occurs far before the dispersal of the gas from the protoplanetary disk. The planetesimal–gaseous disk interactions give rise to migration and orbital evolution of the planetesimals/planets. Small planetesimals are dominated by aerodynamic gas drag. Large protoplanets, m∼0.1M{sub ⊕}, are dominated by type I migration differential torque. There is an additional mass range m∼10{sup 21}−10{sup 25} g of intermediate-mass planetesimals (IMPs), where gravitational interactions with the disk dominate over aerodynamic gas drag, but for which such interactions were typically neglected. Here, we model these interactions using the gas dynamical friction (GDF) approach, previously used to study the disk–planet interactions at the planetary mass range. We find the critical size where GDF dominates over gas drag, and then we study the implications of GDF on single IMPs. We find that planetesimals with small inclinations rapidly become co-planar. Eccentric orbits circularize within a few Myr, provided the the planetesimal mass is large, m≳10{sup 23} g, and that the initial eccentricity is low, e≲0.1. Planetesimals of higher masses, m∼10{sup 24}−10{sup 25} g, inspiral on a timescale of a few Myr, leading to an embryonic migration to the inner disk. This can lead to an overabundance of rocky material (in the form of IMPs) in the inner protoplanetary disk (<1 AU) and induce rapid planetary growth. This can explain the origin of super-Earth planets. In addition, GDF damps the velocities of IMPs, thereby cooling the planetesimal disk and affecting its collisional evolution through quenching the effects of viscous stirring by the large bodies.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Dynamical friction from scalar dark matter in the relativistic regime

Light bosonic scalars (e.g., axions) may form clouds around black holes via superradiant instabilities or via accretion if they form some component of the dark matter. It has been suggested that their presence may lead to a distinctive dephasing of the gravitational wave signal when a small compact object spirals into a larger black hole. Motivated by this, we have studied numerically the dynamical friction force on a black hole moving at relativistic velocities in a background scalar field with an asymptotically homogeneous energy density. Here we show that the relativistic scaling is analogous to that found for supersonic collisional fluids, assuming an approximate expression for the pressure correction which depends on the velocity and scalar mass. While we focus on a complex scalar field, our results confirm the expectation that real scalars would exert a force which oscillates between positive and negative values in time with a frequency set by the scalar mass. The complex field describes the time averaged value of this force, but in a real scalar, the rapid force oscillations could, in principle, leave an imprint on the trajectory. The approximation we obtain can be used to inform estimates of dephasing in the final stages of an extreme mass ratio inspiral.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Shifting and Splitting of Resonance Lines due to Dynamical Friction in Plasmas

We report a quasilinear plasma transport theory that incorporates Fokker-Planck dynamical friction (drag) and pitch angle scattering is self-consistently derived from first principles for an isolated, marginally unstable mode resonating with an energetic minority species. It is found that drag fundamentally changes the structure of the wave-particle resonance, breaking its symmetry and leading to the shifting and splitting of resonance lines. In contrast, scattering broadens the resonance in a symmetric fashion. Comparison with fully nonlinear simulations shows that the proposed quasilinear system preserves the exact instability saturation amplitude and the corresponding particle redistribution of the fully nonlinear theory. Even in situations in which drag leads to a relatively small resonance shift, it still underpins major changes in the redistribution of resonant particles. This novel influence of drag is equally important in plasmas and gravitational systems. In fusion plasmas, the effects are especially pronounced for fast-ion-driven instabilities in tokamaks with low aspect ratio or negative triangularity, as evidenced by past observations. The same theory directly maps to the resonant dynamics of the rotating galactic bar and massive bodies in its orbit, providing new techniques for analyzing galactic dynamics.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

A Polytropic Approximation of Compressible Flow in Pipes With Friction

This paper demonstrates the usefulness of treating subsonic Fanno flow (adiabatic flow, with friction, of a perfect gas in a constant-area pipe) as a polytropic process. It is shown that the polytropic model allows an explicit equation for mass flow rate to be developed. The concept of the energy transfer ratio is used to develop a close approximation to the polytropic index. Explicit equations for mass flow rate and net expansion factor in terms of upstream properties and pressure ratio are developed for Fanno and isothermal flows. An approximation for choked flow is also presented. Here, the deviation of the results of this polytropic approximation from the values obtained from a traditional gas dynamics analysis of subsonic Fanno flow is quantified and discussed, and a typical design engineering problem is analyzed using the new method.

42 ENGINEERING↗
DOE OSTI2020

Mechanical and Corrosion Assessment of Friction Self-Piercing Rivet Joint of Carbon Fiber-Reinforced Polymer and Magnesium Alloy AZ31B

In the present work, thermoset carbon fiber–reinforced polymer (CFRP) was spot joined to magnesium alloy AZ31B by a friction self-piercing riveting (F-SPR) process. Lap shear tensile and cross-tension testing were used to evaluate the mechanical joint performance. An average lap shear tensile load of 5.18 kN was achieved, while an average of 2.81 kN was found from cross-tension testing. All F-SPR samples showed a pullout of AZ31B after mechanical testing, indicating good mechanical interlocking between the steel rivet and AZ31B. Corrosion potential was measured for each material to establish the galvanic corrosion characteristics. As expected, AZ31B was found to be the most active, while thermoset CFRP was the most noble. The steel rivet fell between the AZ31B (active) and the thermoset CFRP (noble). Salt fog corrosion testing (ASTM B-117) was performed to evaluate the corrosion performance of the uncoated F-SPR joint. With up to 200 h of exposure, the post-corroded F-SPR joint integrity retained 81.2% of the pre-exposure F-SPR joint strength with AZ31B pullout failure mode. From cross-sectional analysis of the F-SPR joint, extensive corrosion of AZ31B was observed at the joint and other exposure areas. However, steel rivet was not significantly corroded due to sacrificial anode effect by which AZ31B corroded first in the galvanic couple.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Stationary Shoulder Friction Stir Assisted Scribe Technique for Dissimilar Joining

We report on implementation of a stationary shoulder in dissimilar joints of Al-steel and Al-carbon fiber reinforced polymer (CFRP) using friction stir assisted scribe technology (FaST ). Viable joint strength similar to that with the conventional FAST process was demonstrated in Al-steel. A significant improvement in as-welded surface roughness for both Al-steel and Al-CFRP cases was achieved by using stationary shoulder. Interrupted lap shear tests performed on Al-steel joints and a corresponding computational model indicate the joint failure typically occurs in Al sheet via a crack tip that originates at the steel hook tip on the loading side. A similar fracture path was observed in an Al-CFRP joint.

Das, Hrishikesh↗
DOE OSTI2021

Influence of Tool Runout on Force Measurement During Internal Void Monitoring for Friction Stir Welding of 6061-T6 Aluminum

Abstract The goal of this research was to examine how altering the amount of friction stir tool eccentricity while controlling the amount of slant in the tool shoulder (drivers of oscillatory process forces) effects the generation of process force transients during sub-surface void interaction. The knowledge gained will help improve the accuracy of force-based void monitoring methods that have the potential to reduce the need for post-weld inspection. Process force transients during sub-surface void formation were examined for multiple tools with varying magnitudes of kinematic runout. The eccentric motion of the tool produced oscillations in the process forces at the tools rotational frequency that became distorted when features (flats) on the tool probe interacted with voided volumes, generating an amplitude in the force signals at three times the tool rotational frequency (for three-flat tools). A larger tool eccentricity generates a larger amplitude in the force signals at the tool’s rotational frequency that holds a larger potential to create a distortion during void interaction. It was determined that once void becomes large enough to produce an interaction that generates an amplitude at the third harmonic larger than 30% of the amplitude at the rotational frequency in a weld with no interaction (amplitude solely at rotational frequency), the trailing edge of the tool shoulder cannot fully consolidate the void, i.e., it will remain in the final weld. Additionally, once the void exceeds a certain size, the amplitudes of the third harmonics saturate at 70% of the amplitude at the rotational frequency during full consolidation. The interaction between the eccentric probe and sub-surface void was isolated by ensuring any geometric imperfection in the shoulder (slant) with respect to the rotational axis was removed. The results suggest that geometric imperfections (eccentricity and slant) with respect to the tool’s rotational axis must be known when developing a void monitoring method from force transients of this nature.

Engineering↗
DOE OSTI2020

MECHANICAL AND CORROSION ASSESSMENT OF FRICTION SELF-PIERCING RIVET JOINT OF CARBON FIBER-REINFORCED POLYMER AND MAGNESIUM ALLOY AZ31B

In the present work, thermoset carbon fiber–reinforced polymer (CFRP) was spot joined to magnesium alloy AZ31B by a friction self-piercing riveting (F-SPR) process. Lap shear tensile and cross-tension testing were used to evaluate the mechanical joint performance. An average lap shear tensile load of 5.18 kN was achieved, while an average of 2.81 kN was found from cross-tension testing. All F-SPR samples showed pull-out of AZ31B after mechanical testing, indicating good mechanical interlocking between the steel rivet and AZ31B. Corrosion potential was measured for each material to establish the galvanic corrosion characteristics. As expected, AZ31B was found to be the most active, while thermoset CFRP was the most noble. The steel rivet fell between the AZ31B (active) and the thermoset CFRP (noble). Salt fog corrosion testing (ASTM B-117) was performed to evaluate the corrosion performance of the uncoated F-SPR joint. With up to 200 h of exposure, the post-corroded F-SPR joint integrity retained 81.2% of the pre-exposure F-SPR joint strength with AZ31B pull-out failure mode. From cross-sectional analysis of the F-SPR joint, extensive corrosion of AZ31B was observed at the joint and other exposure areas. However, steel rivet was not significantly corroded potentially due to sacrificial anode effect by which AZ31B corroded first in the galvanic couple.

Lim, Yong Chae↗
DOE OSTI2021

Temperature controlled friction extrusion process

Processing temperature is decisive to the properties and performance of the product in friction extrusion. However, the constantly varying thermal boundary conditions result in an unstable processing temperature even fixed die rotational speed and feed rate were implemented, which extensively disturb the stability of the process and the quality of the product. It is key to maintain the process temperature to ensure the properties of the product is uniform. What's more, a controlled processing temperature enables the properties of the product to be manipulatable between parts and between different locations of one part

Li, Xiao↗
DOE OSTI2022

Maximizing the Proppant Carrying and Viscoelastic Properties of the Bakken Hypersaline-Produced Water with High-Viscosity Friction Reducers for Sustainable Applications

Summary The development and production of unconventional reservoirs, such as the Bakken Formation, have become a resolved mystery for operators in North America since the arrival and advancement of horizontal drilling and hydraulic fracturing technologies. As a result, unconventional reservoir assets became the central focus of the oil and gas industry at the state, national, and global levels. The produced water from these activities in the Bakken Formation have high salt contents (110,000–350,000 ppm) total dissolve solids (TDS) and can pose significant challenges to the environment if not treated. Deep injection into disposal wells is the routine method used to get rid of the Bakken produced water. However, there have been some concerns that unrestrained injections, in addition to polluting the groundwater, could potentially lead to seismic activities either at the time of injection or in the near future. To diminish the environmental impacts that may be associated with induced seismicity, including the reduction of the costs of water acquisition, the produced water can be treated and reused in the hydraulic fracturing processes. Also, the treated water could be used for irrigation purposes, for power generation, and coal mining operations. The issues of waste water and residual oil high in TDS are challenges yet to be effectively addressed despite preceding research and studies on advancing produced water technologies. The goal of this study is to explore all applicable ways by which the produced water from the Bakken Formation can serve as a replacement base fluid for use with polymers like the high-viscosity friction reducers (HVFRs) to create hydraulic fracturing fluids that can be stable with reservoir conditions and also be able to minimize environmental impacts and cost of operations. Experimental investigations using the high-salinity produced water from the Bakken Formation with HVFRs were carried out. The studies included a base case that served as a bench mark for comparing the effectiveness of the other scenarios. The results indicate that the Bakken hyper-saline produced water can withstand effect of heavy metals, salinity, hardness and remain stable through different shear rates (66–330 s−1) when treated with higher dosages [4–8 gal/1,000 gal (gpt)] of HVFRs. Filtration and dilution were the only methods used on the Bakken Formation produced wate for this research

Engineering↗
DOE OSTI2015

Flexible Friction Stir Joining Technology

Reported herein is the final report on a U.S. Department of Energy (DOE) Advanced Manufacturing Office (AMO) project with industry cost-share that was jointly carried out by Oak Ridge National Laboratory (ORNL), ExxonMobil Upstream Research Company (ExxonMobil), and MegaStir Technologies (MegaStir). The project was aimed to advance the state of the art of friction stir welding (FSW) technology, a highly energy-efficient solid-state joining process, for field deployable, on-site fabrications of large, complex and thick-sectioned structures of high-performance and high-temperature materials. The technology innovations developed herein attempted to address two fundamental shortcomings of FSW: 1) the inability for on-site welding and 2) the inability to weld thick section steels, both of which have impeded widespread use of FSW in manufacturing. Through this work, major advance has been made toward transforming FSW technology from a “specialty” process to a mainstream materials joining technology to realize its pervasive energy, environmental, and economic benefits across industry.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Complete Status Report Documenting Development of Friction Stir Welding for Joining Thin Wall Tubing of ODS Alloys

The development of friction stir welding (FSW) for joining thin sections of the advanced oxide dispersion strengthened (ODS) 14YWT ferritic alloy was initiated in Fuel Cycle Research and Development (FCRD), now the Nuclear Technology Research and Development (NTRD), in 2015. The first FSW experiment was conducted in late FY15 and successfully produced a bead-on-plate stir zone (SZ) on a 1 mm thick plate of 14YWT (SM13 heat). The goal of this research task is to ultimately demonstrate that FSW is a feasible method for joining thin wall (0.5 mm thick) tubing of 14YWT.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimization-based algorithms for nonlinear mechanics and frictional contact

An optimization-based strategy for solving nonlinear mechanics problems is proposed. In contrast to typical nonlinear equation solver algorithms that aim to find zeros in the residual force function, we minimize an energy (or energy-like) function to encourage solutions which are locally stable equilibria. These smooth and potentially non-convex objective functions are minimized using a preconditioned conjugate-gradient trust-region algorithm. Contact is formulated as an inequality constrained minimization problem, and is solved with an augmented Lagrangian algorithm. Friction is included in the approach via a regularized quasi-potential energy, and other dissipative behavior is included through the use of variational constitutive updates. Finally, to accelerate convergence rates for the Lagrange multipliers, we propose a novel multiplier update algorithm utilizing the Fischer-Burmeister function, and demonstrate super-linear solver convergence for some applications.

42 ENGINEERING↗
DOE OSTI2022

Sparse Data Machine Learning Integration with Theory, Experiment and Uncertainty Quantification: Process-Structure-Property-Performance of Friction Deformation Processing

Computer vision and deep learning tools that advance the ability to establish processing-structure-property-performance (PSPP) relations are presented. The Bayesian binning method for image segmentation enables quantitative analysis of microstructural features in an automated way, while the analysis of shapes and relative orientation of these features reveals local deformation maps indicative of both, material flow and residual stresses due to materials processing. The deep learning method leads to the previous knowledge agnostic mapping of empirically observed microstructural zones in friction stir welding (FSW) process and synthetic microstructure generation capability that is statistically equivalent to experimentally collected data.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Mirostructure Characterization of Friction Consolidated Copper-Nickel using a Machine Learning Approach: Developing Process to Microstructure Associations

Friction consolidation (FC) is a solid phase processing approach where discrete material forms such as powders, chips, nuggets, etc. are densified via shear deformation. The precursors are placed in a billet container and brought in contact with a rotating tool that applying the desirable amount of normal force. Under the combined action of the rotation and normal pressure, the discrete precursor is consolidated through porosity reduction and shear deformation. FC is increasingly being studied as an attractive approach to manufacturing fully dense parts from powder forms owing to its ability to mix, alloy and consolidate difficult-to-process precursors in minimal number of process steps. Material consolidation and deformation in shear consolidation processes have been studied extensively previously for different material combinations previously. However, despite the extensive research in this area, understanding of the mechanistic processes in pore consolidation, deformation-induced mixing and material solubility during FC is still evolving. Material development using solid phase processing approaches such as FC is often performed based on research experience/education, which can be biased. Conventional analysis and simulation tools in this area tend to be successful only when material thermodynamic pathways and microstructural evolution sequences resulting from processing are clearly defined or known. They are not as effective for emerging advanced manufacturing technologies where material evolution pathways are not well established. The ability to predict optimal process parameters based on material chemistry and bulk properties is essential to accelerate materials design and processing, as are an understanding of the relevant structure-processing-property relationships. These structure-processing-property-performance relationships are at the core of materials science research. Microstructure characterization provides the link to these four core areas, often through visualizing material microstructure using imaging techniques. However, linking microstructure image data (i.e., micrographs) to variables of interest (e.g., processing parameters, material chemistry) in a reproducible, generalizable, and quantitative manner is a significant challenge. Typically, quantitatively linking image data to processing history relies on significant domain knowledge and manual or subject matter expert (SME)-heuristic based image analysis. Such an approach to image analysis has the potential to be biased, inefficient, and difficult to replicate.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Friction Stir Scribe Joining of CFRP to Aluminum (Abstract)

The objective of this project is to develop and demonstrate friction stir scribe (FSS) joining of carbon fiber reinforced polymer (CFRP) to aluminum on light-duty vehicle body-in-white (BIW) joints. The project will also overcome the major obstacles of implementing FSS technology in a fully 3-D production robotic work cell and demonstrate the required CFRP-aluminum joint strengths in industrially relevant light-duty, BIW components. Specifically the project will develop the critical process technology, models and tools necessary to advance the FSS method through experimentation, validation at the laboratory scale, and integration into a production-like robotic environment. The ultimate goal is to demonstrate the technology on industrially relevant components based on process development and numerical simulation performed at scale.

42 ENGINEERING↗