Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “JOINT”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Development of Stable, Low Resistance Solder Joints for a Space-Flight HTS Lead Assemblies

The solder joints in spaceflight high temperature superconductor (HTS) lead assemblies for certain astrophysics missions have strict constraints on size and power dissipation. In addition, the joints must tolerate years of storage at room temperature, many thermal cycles, and several vibration tests between their manufacture and their final operation on orbit. As reported previously, solder joints between REBCO coated conductors and normal metal traces for the Astro-H mission showed low temperature joint resistance that grew approximately as log time over the course of months. Although the assemblies worked without issue in orbit, for the upcoming X-ray Astrophysics Recovery Mission we are attempting to improve our solder process to give lower, more stable, and more consistent joint resistance. We produce numerous sample joints and measure time- and thermal cycle-dependent resistance, and characterize the joints using x-ray and other analysis tools. For a subset of the joints, we use SEMEDS to try to understand the physical and chemical processes that effect joint behavior.

high temperature superconductivity↗
NASA NTRSDate not supplied

Testing and Analysis Correlation of a Large-Scale Composite Sandwich Longitudinal Bonded Joint for Space Launch Vehicle Structures

The NASA Composite Technology for Exploration (CTE) Project is developing and demonstrating critical composite technologies with a focus on composite bonded joints; incorporating materials, design/analysis, manufacturing, and tests that utilize NASA’s expertise and capabilities. The project has goals of advancing composite technologies and providing lightweight structures to support future NASA exploration missions. In particular, the CTE project will demonstrate weight-saving, performance-enhancing composite bonded joint technology for Space Launch System (SLS)-scale composite hardware. Advancements from the CTE project may be incorporated as future block upgrades for SLS structural components. This paper discusses the details of the development of a composite sandwich bonded longitudinal joint for a generic space launch vehicle structure called the CTE Point Design. This paper reports on the large-scale longitudinal bonded joint test articles that were fabricated and tested under axial compressive loading conditions to test the capability of the bonded joint design for buckling and joint failure. Test and analysis correlation of an as-manufactured undamaged longitudinal bonded joint panel are presented in the paper for tests to the onset of buckling and panel failure. Analysis predictions for buckling initiation and panel failure were both within 10% of the longitudinal bonded joint panel test results. This testing and analysis provide confidence in the potential use of composite bonded joints for future launch vehicle structures.

David W Sleight↗
NASA NTRSDate not supplied

Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) Hinge Joint Structural Performance

The Tendon Actuated Lightweight In-Space MANipulator (TALISMAN), invented and initially developed under the Space Technology Mission Directorate Human Robotics Systems program, is a tendon-actuated robot that established a new structural architecture for long-reach space manipulators. The TALISMAN is designed to have significant stiffness and strength in the plane of the tendons or cables, and operations are designed such that all primary loads are applied in that same plane. However, during normal operations it is possible for out-of-plane forces to be applied on the TALISMAN when secondary loads are imparted by a tool or action at the wrist. These secondary loading conditions will induce out-of-plane bending loads in the TALISMAN hinge joints. The TALISMAN hinge joints must be designed for these out-of-plane loads, to ensure no failure of the joint occurs during operations. A series hinge joint out-of-plane stiffness tests were conducted at five different joint angles; at three cable pre-loads from 25-lbf to 100-lbf; up to an equivalent out-of-plane tip load of 27.28-lbf at the end of a 51-in. long distal link. The objective of the tests was to provide an initial set of deflection, cable load, and strain data to inform accurate modeling of the hinge joint out-of-plane stiffness. The test objective was achieved by developing an FEM of the hinge joint able to predict tip displacement to within 10% of values measured in tests. The hinge joint FEM may now be implemented into a full-scale analysis model of the TALISMAN V2.0 to provide predictions of out-of-plane displacement under different load and joint angle conditions.

Matthew K Mahlin↗
NASA NTRSDate not supplied

Material Variability Effects on Damage Development Within Composite Adhesively Bonded Joints

Use of composite adhesively bonded joints (ABJ) is of critical importance to the adoption of composite materials in the automotive industry, as ABJ enable lower stress concentrations as compared to conventional mechanically fastened joints. ABJ are better suited for joining composite materials as compared to fastened joints because fastened joints require drilling of holes which locally affect composite material structure. Composite materials and adhesives are subject to unavoidable stochastic local material variations which make different failure scenarios possible. An experimentally tested ABJ configuration is simulated using finite element analysis (FEA). Experimentally, under tension, the joints failed by three major failure modes, with peak loads ranging from 13.0-16.1 kips. Progressive failure analysis tools are used to simulate damage development within each material within the joint. The simulation agreed well with the average experimental peak load. Stochastically occurring adhesive porosity and matrix-fiber micro-disbonding were numerically simulated. The simulations revealed a similar trend as observed experimentally: joints which failed at higher peak loads had lower levels of damage within the face-sheets of the composite panels which were adhesively bonded; these joints which failed at higher peak loads also had greater damage in the doubler of the experimentally tested double lap joint configuration.

Richard Larson↗
DOE OSTI2018

Enhanced Strength of 304 SS-Ti6Al4V Laser-Welded Joints Containing Composite Interlayers

This paper investigates the microstructural characterization of the fracture propagation edge during laser beam welding of Ti6Al4V and 304 stainless steel using Cu, V, and Ni interlayers as a single Cu interlayer and composite interlayer structures with different Cu interlayer thicknesses. This study attempts to increase the Ti-SS joint strength through the use of the composite interlayers. X-ray diffraction characterization based on a 0.5-mm-thick Cu interlayer showed that the SS/Cu/Ti joint contained considerable brittle IMCs; however, the fracture surface of the SS/Cu-V/Ti composite interlayer sample did not contain any Fe-Ti IMCs or Cr{sub 2}Ti. EBSD observation indicated that the crack propagated transgranularly from solidified CuTi in the interdendritic regions of the FeTi compounds in the composite interlayer sample; however, the crack propagated intergranularly along Fe{sub 2}Ti grain boundaries in the single interlayer sample. The investigation based on a 1-mm-thick Cu interlayer showed that the SS/Ni-Cu1/Ti sample was stronger than the SS/Cu1/Ti sample due to a lack of CuTi at 3.5 kW. The tensile strength of the SS/Cu1-V/Ti joint was greater than that of the SS/Ni-Cu1/Ti joint due to the formation of ductile NiTi instead of brittle NiTi{sub 2}. The microstructures of the fracture edges after tensile testing illustrated that the eutectic CuTi + CuTi{sub 2} fractured at the SS/Cu1/Ti joint after tensile testing, while CuTi{sub 2} and eutectoid αTi + CuTi{sub 2} compounds fractured during the tensile experiment at the SS/Ni-Cu1/Ti and SS/Cu1-V/Ti joints, respectively. Investigations based on both the 0.5- and 1-mm-thick Cu interlayers showed that the tensile strength and elongation of the composite interlayer joints at a laser power of 3.5 kW were greater than those of the single interlayer joints.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Additive manufacturing of functionally graded transition joints between ferritic and austenitic alloys

Dissimilar metal joints between ferritic and austenitic alloys are susceptible to premature failure due to diffusive carbon loss from the ferritic alloy driven by abrupt changes in carbon chemical potential. Compositional grading of transition joints fabricated using laser-based directed energy deposition additive manufacturing offers a means for limiting carbon diffusion. In this report we fabricate functionally graded transition joints between a ferritic and austenitic alloy, characterize spatial variations of chemical composition, microstructure and hardness, and test their effectiveness to limit carbon loss from the ferritic alloy. Microstructural studies and carbon potential variations in the functionally graded material showed that the length of the joints can be shorter, and there is no benefit to continue compositional grading once the microstructure becomes fully austenitic. Since dissimilar joints have an expected lifetime of several decades, long service times were simulated through accelerated heat treatment experiments at elevated temperatures for both a dissimilar metal weld and a functionally graded transition joint. While the dissimilar weld showed pronounced carbon loss from the ferritic side, there was insignificant change in the carbon concentration profile in the functionally graded joint indicating effectiveness of the graded joints to perform under service conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Al-Si Coating on Weld Microstructure and Properties of 22MnB5 Steel Joints for Hot Stamping

22MnB5 hot stamping steels are gradually being used in tailor-welded blank applications. In this experiment, 1-mm-thick Al-Si coated and de-coated 22MnB5 steels were laser-welded and then hot-stamped. The chemical compositions, solidification process, microstructure and mechanical properties were investigated to reveal the effect of Al-Si coating and heat treatment. In the welded condition, the coated joints had an Al content of approximately 2.5 wt.% in the fusion zone and the de-coated joints had 0.5 wt.% Al. The aluminum promoted the δ-ferrite formation as the skeletal structure during solidification. In the high-aluminum weld, the microstructure consisted of martensite and long and band-like δ-ferrite. Meanwhile, the low-aluminum weld was full of lath martensite. After the hot stamping process, the δ-ferrite fraction increased from 10 to 24% in the coated joints and the lath martensite became finer in the de-coated joints. The tensile strengths of the coated joints or de-coated joints were similar to that before hot stamping, but the strength of the coated joints was reduced heavily after hot stamping compared to the de-coated joints and base material. The effect of δ-ferrite on the tensile properties became stronger when the fusion zone was soft and deformed first in the hot-stamped specimens. The coated weld showed a brittle fracture surface with many cleavage planes, and the de-coated weld showed a ductile fracture surface with many dimples in hot-stamped conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Base Metal Misorientation on Single-Crystal Superalloy Transient Liquid-Phase Bonded Joints

In this paper, experiments and theoretical analysis were conducted to elucidate the internal relation between base metal misorientation and the characteristics of DD5 single-crystal superalloy TLP joints. The alloy was bonded at 1513 K for 10 h in vacuum environment. High-temperature creep rupture tests were carried out to determine the joint’s quality. Results revealed that base metal misorientation exerted a remarkable influence on DD5 alloy TLP joints. The joints of base metals with [001] orientation were used in this research. When the misorientation was smaller than 9°-10°, the single crystallization of joints can be realized and joints can achieve excellent mechanical properties. When the misorientation was more than 10°, there would be second-phase particles distributed in grain boundaries, thus resulting in poor mechanical property of joint; moreover, the characteristics of joint did not change with base metal misorientation in this case.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure evolution, grain morphology variation and mechanical property change of Cu-Sn intermetallic joints subjected to high-temperature aging

Highlights: • The δ-Cu{sub 41}Sn{sub 11} could be formed by reaction of 11Cu{sub 3}Sn + 9Cu → Cu{sub 41}Sn{sub 11} during aging above 350 °C. • The temperature effects on the growth rate and grain morphology of Cu{sub 41}Sn{sub 11} phase were found. • The Cu{sub 41}Sn{sub 11} joints with refined grains exhibited higher hardness and shear strength. • The Cu{sub 41}Sn{sub 11} joints exhibited a combination of transgranular and intergranular fracture during shear test. - Abstract: In this work, the aging treatment was carried out on full Cu{sub 3}Sn joints at different temperatures for various durations, the microstructure evolution, grain morphology variation and mechanical property change of joints were investigated. The temperature effects on the growth rate and grain morphology of Cu{sub 41}Sn{sub 11} phase were found: The complete transformation from Cu{sub 3}Sn phase to Cu{sub 41}Sn{sub 11} phase in joints needed 300 h at 400 °C, but 4 h at 500 °C. The Cu{sub 41}Sn{sub 11} phase formed at 400 °C consisted of columnar grains with an average width of 23.5 μm, while the Cu{sub 41}Sn{sub 11} phase formed at 500 °C consisted columnar grains with an average width of 8.5 μm. The average hardness and shear strength values of the Cu{sub 41}Sn{sub 11} joints formed at 400 °C were 432.5 HV and 62 MPa, while the joints formed at 500 °C exhibited higher hardness and shear strength (451.5 HV and 65 MPa). Besides, the Cu{sub 41}Sn{sub 11} joint was found to exhibit a combination of transgranular and intergranular fracture during shear test.

36 MATERIALS SCIENCE↗
DOE OSTI2014

TH-A-18C-02: An Electrostatic Model for Assessment of Joint Space Morphology in Cone-Beam CT

Purpose: High-resolution cone-beam CT (CBCT) of the extremities presents a potentially valuable basis for image-based biomarkers of arthritis, trauma, and risk of injury. We present a new method for 3D joint space analysis that exploits the high isotropic spatial resolution of CBCT and is sensitive to small changes in disease-related morphology. Methods: The approach uses an “electrostatic” model in which joint surfaces (e.g., distal femur and proximal tibia) are labeled as charge densities between which the electric field is solved by approximation to the Laplace equation. The method yields a unique solution determined by the field lines across the “capacitor” and is hypothesized to be more sensitive than conventional (Sharp) scores and immune to degeneracies that limit simple distance-along-axis or closest-point analysis. The algorithm was validated in CBCT phantom images and applied in two clinical scenarios: osteoarthritis (OA, change in loadbearing tibiofemoral joint space); and assessment of injury risk (correlation of 3D joint space to tibial slope). Results: Joint space maps computed from the electrostatic model were accurate to within the voxel size (0.26 mm). The method highlighted subtle regions of morphological change that would likely be missed by conventional scalar metrics. Regions of subtle cartilage erosion were well quantified, and the method confidently discriminated OA and non-OA cohorts. 3D joint space maps correlated well with tibial slope and provide a new basis for principal component analysis of loadbearing injury risk. Runtime was less than 5 min (235×235×121 voxel subvolume in Matlab). Conclusion: A new method for joint space assessment was reported as a possible image-based biomarker of subtle articular change. The algorithm yields accurate quantitation of the joint in a manner that is robust against operator and patient setup variation. The method shows promising initial results in ongoing trials of CBCT in osteoarthritis, rheumatoid arthritis, and injury risk assessment. Research supported by R01 and R21 grants from the National Institutes of Health, academic-industry partnership with Carestream Health, and a grant from the US Army Natick Soldier Research, Development and Engineering Center.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2012

Majorana Demonstrator Bolted Joint Mechanical and Thermal Analysis

The MAJORANA DEMONSTRATOR is designed to probe for neutrinoless double-beta decay, an extremely rare process with a half-life in the order of 10 26 years. The experiment uses an ultra-low background, high-purity germanium detector array. The germanium crystals are both the source and the detector in this experiment. Operating these crystals as ionizing radiation detectors requires having them under cryogenic conditions (below 90 K). A liquid nitrogen thermosyphon is used to extract the heat from the detectors. The detector channels are arranged in strings and thermally coupled to the thermosyphon through a cold plate. The cold plate is joined to the thermosyphon by a bolted joint. This circular plate is housed inside the cryostat can. This document provides a detailed study of the bolted joint that connects the cold plate and the thermosyphon. An analysis of the mechanical and thermal properties of this bolted joint is presented. The force applied to the joint is derived from the torque applied to each one of the six bolts that form the joint. The thermal conductivity of the joint is measured as a function of applied force. The required heat conductivity for a successful experiment is the combination of the thermal conductivity of the detector string and this joint. The thermal behavior of the joint is experimentally implemented and analyzed in this study.

Aguayo Navarrete, Estanislao↗
DOE OSTI2014

The Cost of Jointness: Insights from Environmental Monitoring Systems in Low-Earth Orbit

This report summarizes the results of doctoral research that explored the cost impact of acquiring complex government systems jointly. The report begins by reviewing recent evidence that suggests that joint programs experience greater cost growth than non-joint programs. It continues by proposing an alternative approach for studying cost growth on government acquisition programs and demonstrates the utility of this approach by applying it to study the cost of jointness on three past programs that developed environmental monitoring systems for low-Earth orbit. Ultimately, the report concludes that joint programs' costs grow when the collaborating government agencies take action to retain or regain their autonomy. The report provides detailed qualitative and quantitative data in support of this conclusion and generalizes its findings to other joint programs that were not explicitly studied here. Finally, it concludes by presenting a quantitative model that assesses the cost impacts of jointness and by demonstrating how government agencies can more effectively architect joint programs in the future.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

Investigation of Energy Dissipation Behavior in Threaded Joints Under Impact Loading Using a Kolsky Tension Bar

Threaded joints are a common fastening method in applications where disassembly may be required. With a fair amount of investigation of static behavior of threaded joints, less emphasis has been placed on the behavior of threaded joints subjected to transient impact loads. Understanding how energy is transferred across threaded joints under impact loading conditions is critical for improved design and optimization for extreme mechanical environments. Many factors, such as pre - torque, pre - tension load, and impact speed can affect how energy is transferred or dissipated across threaded joins. In addition, high-fidelity numerical simulation of mechanical response of threaded components under blast or impact loading requires reliable experiments and subsequent analyses. In this study, the energy dissipation behavior through a threaded joint under impact loading conditions is investigated using a Kolsky tension bar. The aim is to study possible energy dissipation behavior in both time and frequency domains while the threaded joint remains intact. New analytical methods to understand both time-and frequency-domain behavior of threaded joints are presented. Energy dissipation characteristics through steel-to-steel and steel-to-aluminum threaded joints were then investigated with varying parameters such as pre-torque and impact velocity.

42 ENGINEERING↗
DOE OSTI2026

Demonstration of high-rate manufacturing of π-joint using additive manufacturing

Bonded composite π-joints are critical to support wing geometries in aerospace/aircraft structures. Its lightweight and robust load-bearing capabilities/design guarantee high structural integrity and reliability. Current manufacturing techniques of π-joints are complex and laborious, and do not always offer high-quality joining. This study presents a high-rate manufacturing approach to fabricate π-joints using an integrated Additive Manufacturing and Compression Molding (AMCM) process. The joints were manufactured using unidirectional aerospace-grade LMPAEK/CF at 60% fiber loading for the stiffeners/skin and LM-PAEK/GF as the adhesive and characterized to evaluate their microstructure and strength. While the results indicate void formation at the joint caused by inadequate pressure, the peak tensile load of 600N recorded is akin to injection-autoclave molded π-joints, which validates the potential of this high-rate integrated approach to eliminate time-consuming and labour-intensive processes of making π-joints to reduce cost and produce high-quality joints.

Marathe, Umesh [ORNL]↗
NASA NTRS1976

Bolted joints in graphite-epoxy composites

All-graphite/epoxy laminates and hybrid graphite-glass/epoxy laminates were tested. The tests encompassed a range of geometries for each laminate pattern to cover the three basic failure modes - net section tension failure through the bolt hole, bearing and shearout. Static tensile and compressive loads were applied. A constant bolt diameter of 6.35 mm (0.25 in.) was used in the tests. The interaction of stress concentrations associated with multi-row bolted joints was investigated by testing single- and double-row bolted joints and open-hole specimens in tension. For tension loading, linear interaction was found to exist between the bearing stress reacted at a given bolt hole and the remaining tension stress running by that hole to be reacted elsewhere. The interaction under compressive loading was found to be non-linear. Comparative tests were run using single-lap bolted joints and double-lap joints with pin connection. Both of these joint types exhibited lower strengths than were demonstrated by the corresponding double-lap joints. The analysis methods developed here for single bolt joints are shown to be capable of predicting the behavior of multi-row joints.

Hart-Smith, L. J.↗
NASA NTRS1978

Spacesuit mobility joints

Joints for use in interconnecting adjacent segments of an hermetically sealed spacesuit which have low torques, low leakage and a high degree of reliability are described. Each of the joints is a special purpose joint characterized by substantially constant volume and low torque characteristics. Linkages which restrain the joint from longitudinal distension and a flexible, substantially impermeable diaphragm of tubular configuration spanning the distance between pivotally supported annuli are featured. The diaphragms of selected joints include rolling convolutions for balancing the joints, while various joints include wedge-shaped sections which enhance the range of motion for the joints.

Vykukal, H. C.↗
NASA NTRS1979

Spacesuit mobility knee joints

Pressure suit mobility joints are for use in interconnecting adjacent segments of an hermetically sealed spacesuit in which low torques, low leakage and a high degree of reliability are required. Each of the joints is a special purpose joint characterized by substantially constant volume and low torque characteristics and includes linkages which restrain the joint from longitudinal distension and includes a flexible, substantially impermeable diaphragm of tubular configuration spanning the distance between pivotally supported annuli. The diaphragms of selected joints include rolling convolutions for balancing the joints, while various joints include wedge-shaped sections which enhance the range of motion for the joints.

Vykukal, H. C.↗
NASA NTRS1986

Measuring Hole Elongation in Bolted Joints

Measurement does not affect joint parameters. Verification of analytical and strength-prediction methods for bolted composite joints based generally on data obtained experimentally from double-lap-joint specimens. In mechanically fastened joints, stresses maximal at fastener holes. Ability to measure accurately hole elongations without affecting joint parameters provides better understanding of elastic and plastic behavior of joint material leading to failure mechanisms in mechanically fastened joints required for design of more-efficient, lightweight composite joints.

Wichorek, G. R.↗