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At least 163 records · Page 9

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NASA NTRS2004

Heat Control via Torque Control in Friction Stir Welding

In a proposed advance in friction stir welding, the torque exerted on the workpiece by the friction stir pin would be measured and controlled in an effort to measure and control the total heat input to the workpiece. The total heat input to the workpiece is an important parameter of any welding process (fusion or friction stir welding). In fusion welding, measurement and control of heat input is a difficult problem. However, in friction stir welding, the basic principle of operation affords the potential of a straightforward solution: Neglecting thermal losses through the pin and the spindle that supports it, the rate of heat input to the workpiece is the product of the torque and the speed of rotation of the friction stir weld pin and, hence, of the spindle. Therefore, if one acquires and suitably processes data on torque and rotation and controls the torque, the rotation, or both, one should be able to control the heat input into the workpiece. In conventional practice in friction stir welding, one uses feedback control of the spindle motor to maintain a constant speed of rotation. According to the proposal, one would not maintain a constant speed of rotation: Instead, one would use feedback control to maintain a constant torque and would measure the speed of rotation while allowing it to vary. The torque exerted on the workpiece would be estimated as the product of (1) the torque-multiplication ratio of the spindle belt and/or gear drive, (2) the force measured by a load cell mechanically coupled to the spindle motor, and (3) the moment arm of the load cell. Hence, the output of the load cell would be used as a feedback signal for controlling the torque (see figure).

Venable, Richard↗

NASA NTRS2013

Friction Stir Weld Application and Tooling Design for the Multi-purpose Crew Vehicle Stage Adapter

The Multi-Purpose Crew Vehicle (MPCV), commonly known as the Orion capsule, is planned to be the United States' next manned spacecraft for missions beyond low earth orbit. Following the cancellation of the Constellation program and creation of SLS (Space Launch System), the need arose for the MPCV to utilize the Delta IV Heavy rocket for a test launch scheduled for 2014 instead of the previously planned Ares I rocket. As a result, an adapter (MSA) must be used in conjunction with the MPCV to account for the variation in diameter of the launch vehicles; 5.5 meters down to 5.0 meters. Prior to ight article fabrication, a path nder (test article) will be fabricated to ne tune the associated manufacturing processes. The adapter will be comprised of an aluminum frustum (partial cone) that employs isogrid technology and circumferential rings on each end. The frustum will be fabricated by friction stir welding (FSW) three individual panels together on a Vertical Weld Tool (VWT) at NASA Marshall Space Flight Center. Subsequently, each circumferential ring will be friction stir welded to the frustum using a Robotic Weld Tool (RWT). The irregular geometry and large mass of the MSA require that extensive tooling preparation be put into support structures for the friction stir weld. The tooling on the VWT will be comprised of a set of conveyors mounted on pre-existing stanchions so that the MSA will have the ability to be rotated after each of the three friction stir welds. The tooling requirements to friction stir weld the rings with the RWT are somewhat more demanding. To support the mass of the MSA and resist the load of the weld tool, a system of mandrels will be mounted to stanchions and assembled in a circle. The goal of the paper will be to explain the design, fabrication, and assembly of the tooling, to explain the use of friction stir welding on the MSA path nder, and also to discuss the lessons learned and modi cations made in preparation for ight article fabrication in support of the 2014 launch of the Orion MPCV.

Alcorn, John↗

DOE OSTI2018

Isotope- and Thickness-Dependent Friction of Water Layers Intercalated Between Graphene and Mica

The lubricating properties of water have been discussed extensively for millennia. Water films can exhibit wearless high friction in the form of cold ice, or act as lubricants in skating and skiing when a liquid. At the fundamental level, friction is the result of a balance between the rate of energy generation by phonon excitation during sliding and drainage of the energy from the interface by coupling with bulk atoms. Using atomic force microscopy, we found that when H 2 O intercalates between graphene and mica, it increases the friction between the tip and the substrate, dependent on the thickness of the water and graphene layers, while the magnitude of the increase in friction was reduced by D 2 O intercalation. With the help of first-principles density functional theory calculations, we explain this unexpected behavior by the increased spectral range of the vibration modes of graphene caused by water, and by better overlap of the graphene vibration modes with mica phonons, which favors more efficient energy dissipation. Finally, the larger increase in friction with H 2 O versus D 2 O shows that the high-frequency vibration modes of the water molecules play a very important role in the transfer of the vibrational energy of the graphene to the phonon bath of the substrate.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Mechanical Properties, Microstructural Evolution, and the Effect of Friction on the Plastic Flow of the AISI 321 Austenitic Stainless Steel Tube During Cold Pilgering: An Experimental and Simulation Analysis

The mechanical properties, microstructural evolution, and the effect of friction on the plastic flow of the AISI 321 austenitic stainless steel (ASS) tube were investigated during the cold pilger process. The elastic–plastic behavior of as-received tube was simulated by the Johnson-cook model. The model parameters were obtained by the compression and tensile tests. The mechanical properties of the material were examined by the tensile and microhardness tests. Based on the ring compression test results, three different situations for friction conditions were considered. The stress and strain states at these conditions were examined for the outer and inner surfaces of the tube. Numerical evaluation of plastic shearing due to the cold pilgering of the AISI321 tube was performed. The X-ray diffraction, ferrite scope tests, and optical microscope were also used for the microstructure evaluation and verification of the simulation results, respectively. The Latham-Cockcraft damage was calculated for different conditions by introducing the new subroutine, showing that it was strongly dependent on the friction conditions and the shear strain, ε{sub zr}, respectively. It was shown that the friction coefficient of 0.3 resulted in the minimum damage of the tube and the different friction conditions between the two surfaces of the tube enhanced the damage function. Also, the strain induced ά-martensite increased the work-hardening capacity and affected the ductility of the tube.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Determination of the Frictional Behavior at Compaction of Powder Materials Consisting of Spray-Dried Granules

The frictional behavior during powder compaction and ejection is studied using an instrumented die with eight radial sensors. The average friction over the total powder pillar is used to determine a local friction coefficient at each sensor. By comparing forces at compaction with forces at ejection, it can be shown that the Coulomb’s friction coefficient can be described as a function of normal pressure. Also stick phenomena has been investigated in order to assess its influence on the determination of the local friction coefficient.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Nonuniformity in Mechanical Properties of Linear Friction Welded Mild Steel Joint

Mild steel was successfully joined by linear friction welding. Grain size at peripheral region was coarser than that at the other zones of the weld interface, which had no significant effect on microhardness. The local tensile properties were considerably decreased when oxides or lack of bonding appeared at the interface. Ductile fracture dominated the fracture mode for all joints. Variation in local tensile properties could be relieved under a medium friction pressure, a relatively high amplitude with a sufficient friction time. It was attributed to the facts that plastic metal layer of joint became uniform to some extent and interfacial defects were eliminated. The standard deviation of plastic metal layer thickness (χ{sub p}) could be used to describe the combined effects of welding parameters on joint integral performance. It was found that the standard deviation of plastic metal layer thickness showed a strong inverse correlation with the joint integral performance. Well-formed and defect-free joints exhibiting 90% of the base metal tensile strength could be produced when processing at a frequency of 20 Hz with a friction pressure of 103 MPa or 155 MPa, an amplitude of 2.5 mm and a friction time of at least 4 s.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Frictional Contacts Between Individual Woody Biomass Particles under Wet and Dry Conditions

Friction between wood particles can be a critical property when designing processing equipment for creating cellulosic biofuels and similar natural products. Also, as wood processing is likely to occur year-round, understanding the friction between wet as well as dry wood particles can help design and model equipment, such as screw feeders. Here, a tribo-rheometry method was developed using a commercial rheometer that measured the torque required to rotate two contacting millimeter-scale wood chip particles. First, a range of normal forces were used to find the limits of the experimental method. Torque values were measured for seven pairs of wood chip particles at 1 N normal force under both dry and wet conditions, at both ambient conditions and in a humidity-controlled chamber. The torque required to rotate the wet particles was consistently higher than that of the dry particles, although differences were not quite statistically significant when measurements were performed at ambient conditions. Using humidity control resulted in torque values for wet particles of 1900 uNm and 900 uNm for dry particles. Finally, the friction coefficient was calculated as 0.23 for wet particles and 0.11 for dry particles when humidity was controlled. These frictions coefficients agreed with values for wood reported in the literature. Overall, controlling humidity is strongly recommended to quantify the range of friction for particles that uptake water, including granular systems from biomass to food to powders.

biomass↗

DOE OSTI2026

Sliding friction and wear behavior of nuclear graphite in high temperature inert environment: Influence of contact load, speed and temperature

Repeated dynamic interactions of graphitic components in pebble-bed gas-cooled nuclear reactors can cause abrasive wear-induced pebble surface damage, generate hazardous fine graphite debris, and alter fuel circulation dynamics due to changes in friction behavior. Comprehensive tribological characterization of nuclear graphitic materials in conditions relevant to reactor operation is needed to assess reactor long-term safety and performance. This work reports sliding friction and wear behavior of self-mated nuclear graphite ET-10 at various elevated temperatures (650 °C and 750 °C), sliding speeds (1 and 10 mm/s) and contact loads (20 and 40 N) in a controlled argon environment. The results revealed nonmonotonic frictional behavior with a higher running-in coefficient of friction (COF) followed by a lower steady-state COF, as a result of transition from two-body abrasion to three-body abrasion along with formation of a tribofilm. A key finding of this work is the sensitivity of the running-in COF to experimental conditions; maximum running-in values were lower at either elevated temperature (0.52–0.54) or reduced sliding speed (0.51–0.54). Conversely, the steady-state COF remained invariant at approximately 0.3 across all tested parameters. Transmission electron microscopy revealed a 0.5–2.0 μm thick nanocrystalline tribofilm that was thought to be formed by the compaction of the graphitic wear debris on the contact surface during the sliding process. The nanocrystalline nature of the tribofilm was further confirmed by Raman spectroscopy. As a result, the combination of tribological testing and morphological characterization provided a mechanistic understanding of the frictional behavior of nuclear graphite upon sliding.

Friction↗

DOE OSTI2026

Designing Thermomechanically Stable Nanocrystalline Alloys for Low Friction and Wear: A Perspective

In this Perspective, we discuss recent work and future trends on the usage of thermomechanically stable and selflubricating nanocrystalline (NC) alloys for low friction and wear applications. The theoretical underpinnings and mechanistic framework for attaining and maintaining low friction and wear in metal contacts are presented. Initial work on stress, time, and temperature-dependent changes in friction and wear in NC alloys validates the models, demonstrating lower friction from decreased interfacial strength, contact pressure, sliding speed, and temperature and increased roughness and material hardness. Subsequent work reveals that NC Pt−Au, metal nitrides, complex-concentrated, and high-entropy alloys come with additional stabilization factors such as low-friction carbon tribofilms and oxide/amorphous−crystalline layers but are still susceptible to destabilization factors including irradiation and adverse environmental conditions.

alloys↗

DOE OSTI2018

Squeezing and stick–slip friction behaviors of lubricants in boundary lubrication

The fundamental questions of how lubricant molecules organize into a layered structure under nanometers confinement and what is the interplay between layering and friction are still not well answered in the field of nanotribology. While the phase transition of lubricants during a squeeze-out process under compression is a long-standing controversial debate (i.e., liquid-like to solid-like phase transition versus amorphous glass-like transition), recent different interpretations to the stick–slip friction of lubricants in boundary lubrication present new challenges in this field. Here, we carry out molecular dynamics simulations of a model lubricant film (cyclohexane) confined between molecularly smooth surfaces (mica)––a prototypical model system studied in surface force apparatus or surface force balance experiments. Through fully atomistic simulations, we find that repulsive force between two solid surfaces starts at about seven lubricant layers ( n = 7) and the lubricant film undergoes a sudden liquid-like to solid-like phase transition at n < 6 monolayers thickness. Shear of solidified lubricant films at three- or four-monolayer thickness results in stick–slip friction. The sliding friction simulation shows that instead of shear melting of the film during the slip of the surface, boundary slips at solid–lubricant interfaces happen, while the solidified structure of the lubricant film is well maintained during repeated stick–slip friction cycles. Moreover, no dilation of the lubricant film during the slip is observed, which is surprisingly consistent with recent surface force balance experimental measurements.

42 ENGINEERING↗

DOE OSTI2022

Seabed bathymetry and friction modeling in MoorDyn

This paper presents the implementation and verification of a seabed bathymetry feature and seabed friction feature to the open-source, lumped-mass mooring system dynamics modeler, MoorDyn, which is part of the National Renewable Energy Laboratory’s aero-hydro-servo-elastic simulation tool, OpenFAST. Variations in seabed slope, as well as the frictional effects of mooring lines moving along the seabed, will affect the mooring line tensions of a floating platform and the consequent platform response. These new features are especially relevant for modeling mooring systems in deep-water coastal areas where seabed depth can change significantly over an entire mooring footprint. The bathymetry feature models the seabed as a rectangular grid of variable water depths in place of the existing, uniform water depth in MoorDyn. The friction force is primarily represented as a Coulombic friction force, or the product of a kinetic friction coefficient and the seabed contact normal force, with the ability to differentiate between transverse and axial motion of a line node on the seabed in any bathymetry grid. These capabilities were tested by running MoorDyn and OpenFAST simulations over a variety of seabed and environmental conditions; the resulting fairlead tensions, node tensions, and mooring line kinematics were verified against equivalent OrcaFlex simulations. The results match closely, meaning the features are verified, which will increase the overall fidelity of OpenFAST and FAST.Farm simulations.

17 WIND ENERGY↗

DOE OSTI2020

Transient Microstructure Evolutions and Local Properties of Dual-Phase 980 MPa Grade Steel Via Friction Stir Spot Processing

Friction stir processing is a novel solid-state process to modify microstructures and their properties by intense, localized plastic deformation. However, little research has been reported for microstructure evolutions of advanced high-strength steels during the process. The present work focuses on the study of transient microstructure changes and local mechanical properties for friction stir spot processed dual-phase (DP) 980 MPa grade steel (DP980) under different peak temperatures. A pinless silicon nitride ceramic tool was used to produce relatively simple material deformation and flow near the tool. Friction stir spot processed steel samples were characterized by optical and electron microscopies. Furthermore, Vickers microhardness and nano-indentation measurements were used to study local mechanical properties for correlation with microstructures. A swallow layer of refined grains (<0.6 µm) was obtained with a low peak temperature (under 400 °C), whereas higher peak temperatures (>Ac 1 ) led to a change in grain size with different microstructures (fine-grained DP or martensite). Electron back-scattered diffraction characterizations revealed a large deformation in the as-received microstructures (mixture of ferrite and tempered martensite) induced by friction stir spot processing, leading to recrystallization and grain refinement around the stirred zone. Also, nano-indentation measurements showed a higher hardness than the hardness of the as-received DP980. Friction stir processing with different process conditions effectively changed microstructures and local mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Dissimilar Materials Joining of Carbon Fiber Polymer to Dual Phase 980 by Friction Bit Joining, Adhesive Bonding, and Weldbonding

In the present study, joining of a carbon fiber-reinforced polymer and dual phase 980 steel was studied using the friction bit joining, adhesive bonding, and weldbonding processes. The friction bit joining process was optimized for the maximum joint strength by varying the process parameters. Then, the adhesive bonding and weld bonding (friction bit joining plus adhesive bonding) processes were further developed. Lap shear tensile and cross-tension testing were used to assess the joint integrity of each process. Fractured specimens were compared for the individual processes. The microstructures in the joining bit ranged from tempered martensite to fully martensite in the cross-section view of friction bit-joined specimens. Additionally, the thermal decomposition temperature of the as-received carbon fiber composite was studied by thermogravimetric analysis. Fourier-transform infrared–attenuated total reflectance spectroscopy and X-ray diffraction measurements showed minimal variations in the absorption peak and diffraction peak patterns, indicating insignificant thermal degradation of the carbon fiber matrix due to friction bit joining.

36 MATERIALS SCIENCE↗

NASA NTRS1952

Friction and Surface Damage of Several Corrosion-resistant Materials

Friction and surface damage of several materials that are resistant to corrosion due to liquid metals was studied in air. The values of kinetic friction coefficient at low sliding velocities and photomicrographs of surface damage were obtained. Appreciable surface damage was evident for all materials tested. The friction coefficients for the combinations of steel, stainless steel, and monel sliding against steel, stainless steel, nickel, Iconel, and Nichrome ranged from 0.55 for the monel-Inconel combination to 0.97 for the stainless-steel-nickel combination; for steel, stainless steel, monel, and tungsten carbide against zirconium, the friction coefficient was approximately 0.47. Lower coefficients of friction (0.20 to 0.60) and negligible surface failure at light loads were obtained with tungsten carbide when used in combination with various plate materials.

ONTACT SURFACES, SLIDING↗

NASA NTRS2021

Skin Friction Extracted from Surface Pressure in Incident Shock-Wave/Boundary-Layer Interaction

High-resolution skin-friction fields are extracted from pressure-sensitive paint (PSP) data obtained in shock-wave/boundary-layer interaction (SWBLI). The method of extracting skin friction from surface pressure is described, including the fundamental relation between skin friction and surface pressure, the variational method, error analysis, and an approximate iterative method. The proposed method is based on a coupling relation between skin friction and surface pressure, where the boundary enstrophy flux is suitably modeled or approximated. This method is applied to unsteady PSP data obtained in incident SWBLIs at Mach 2.5 for different Reynolds numbers, revealing the skin-friction structures of the flows: particularly, the separation bubble induced by the incident shock wave. The extracted results are in good agreement with the data obtained by the surface-stress-sensitive film.

skin friction↗

DOE OSTI2019

FRICTION AND PERMEABILITY EVOLUTION OF FRACUTRES AND FAULTS DURING STATIC REPOSE AND DYNAMIC REACTIVATION

The co-evolution of fault/fracture friction and permeability represent important science/engineering challenges impacting natural and engineered systems. Friction directly controls the characteristics of natural fault slip, including inter-seismic healing, slow creep and earthquake rupture. Permeability evolution during fault slip and repose illuminates our understanding of perturbations to the earthquake-modulated natural hydraulic system and of subsurface engineering in recovering both shale gas and geothermal energy and in the safe subsurface sequestration of CO2. However, mechanisms controlling the evolution of friction and permeability during slow slip, fast rupture and inter-event repose are not clearly understood. For instance, the evolution of stick-slip amplitudes and recurrence, the role of inertia and its influence on frictional stability and the interdependence of these processes remain unclear. Furthermore, mechanisms of permeability evolution during the earthquake cycle (repose through rupture) are also poorly understood since they are influenced in a complex way by chemo-mechanical effects such as elastic/plastic compaction, shear comminution, mechanical dilation, pressure solution and stress corrosion. In this study, we explore fracture friction and permeability evolution during static and dynamic reactivation using both numerical and experimental approaches. This is described in the four chapters of this dissertation.

58 GEOSCIENCES↗

DOE OSTI2023

Axion dark matter from frictional misalignment

We study the impact of sphaleron-induced thermal friction on the axion dark-matter abundance due to the interaction of an axion-like particle (ALP) with a dark non-abelian gauge sector in a secluded thermal bath. Thermal friction can either enhance the axion relic density by delaying the onset of oscillations or suppress it by damping them. We derive an analytical formula for the frictional adiabatic invariant, which remains constant along the axion evolution and which allows us to compute the axion relic density in a general set-up. Even in the most minimal scenario, in which a single gauge group is responsible for both the generation of the ALP mass and the friction force, we find that the resulting dark-matter abundance from the misalignment mechanism deviates from the standard scenario for axion masses m a ≳ 100 eV. We also generalize our analysis to the case where the gauge field that induces friction and the gauge sector responsible for the ALP mass are distinct and their couplings to the axion have a large hierarchy as can be justified by means of alignment or clockwork scenarios. We find that it is easy to open up the ALP parameter space where the resulting axion abundance matches the observed dark-matter relic density both in the traditionally over- and underabundant regimes. This conclusion also holds for the QCD axion.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Linking Friction Scales from Nano to Macro via Avalanches

Abstract Steady-state fluctuations in the friction force of molybdenum disulfide (MoS 2 ), a prototypical lamellar solid, were analyzed experimentally for newton-scale forces and computationally via molecular dynamics simulations for nanonewton-scale forces. A mean field model links the statics and the dynamics of the friction behavior across these eight orders of magnitude in friction force and six orders of magnitude in friction force fluctuations (i.e., avalanches). Both the statistics and dynamics of the avalanches match model predictions, indicating that friction can be characterized as a series of avalanches with properties that are predictable over a wide range of scales.

Salners, Tyler (ORCID:0000000332647944)↗