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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.

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At least 1,711 records · Page 95
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Formation of Oxides in the Interior of Friction Stir Welds

In friction stir welding (FSWing) the actual solid state joining takes place between the faying surfaces which form the weld seam. Thus the seam trace is often investigated for clues when the strength of the weld is reduced. Aluminum and its alloys are known to form a native, protective oxide on the surface. If these native surface oxides are not sufficiently broken up during the FSW process, they are reported to remain in the FSW interior and weaken the bond strength. This type of weld defect has been referred to as a lazy "S", lazy "Z", joint line defect, kissing bond, or residual oxide defect. Usually these defects are mitigated by modification of the process parameters, such as increased tool rotation rate, which causes a finer breakup of the native oxide particles. This study proposes that there may be an alternative mechanism for formation of oxides found within the weld nugget. As the oxidation rate increases at elevated temperatures above 400ºC, it may be possible for enhanced oxidation to occur on the interior surfaces during the FSW process from entrained air entering the seam gap. Normally, FSWs of aluminum alloys are made without a purge gas and it is unknown how process parameters and initial fit up could affect a potential air path into the interior during the processing. In addition, variations in FSW parameters, such as the tool rotation, are known to have a strong influence on the FSW temperature which may affect the oxidation rate if internal surfaces are exposed to entrained air. A series of FSWs were made in 3 different thickness panels of AA2219 (0.95, 1.27 and 1.56 cm) at 2 different weld pitches. As the thickness of the panels increased, there was an increased tendency for a gap to form in advance of the weld tool. If sufficient air is able to enter the workpiece gap prior to consolidation, the weld temperature can increase the oxidation rate on the interior surfaces. These oxidation rates would also be accelerated in areas of localized liquation. Metallographs from the weld panels showed indications of liquation at the grain boundaries. In FSWs of thicker panels, these regions of liquation were found to be heavily oxidized. The quality of the FSWs was evaluated from tensile testing at room temperature. As the panel thickness increased, a slight decrease in tensile strength was observed which was attributed to the presence of oxides. No oxide formation was observed in the thinner workpieces, although there were indications of localized liquation at the grain boundaries. Results from this study will assist in a better understand of the mechanisms of oxide formation in FSW interiors and provide methodology for minimizing their occurrence.

Schneider, Judy↗
NASA NTRS2016

Origins of Line Defects in Self-Reacting Friction Stir Welds and Their Impact on Weld Quality

Friction stir welding (FSWing) is a solid state joining technique which reduces the occurrence of typical defects formed in fusion welds, especially of highly alloyed metals. Although the process is robust for aluminum alloys, occasional reductions in the strength of FSWs have been observed. Shortly after the NASA-MSFC implemented a variation of FSW called self-reacting (SR), low strength properties were observed. At that time, this reduction in strength was attributed to a line defect. At that time, the limited data suggested that the line defect was related to the accumulation of native oxides that form on the weld lands and faying surfaces. Through a series of improved cleaning methods, tool redesign, and process parameter modifications, the reduction in the strength of the SR-FSWs was eliminated. As more data has been collected, the occasional reduction in the strength of SR-FSW still occurs. These occasional reductions indicate a need to reexamine the underlying causes. This study builds off a series of self reacting (SR)-FSWs that were made in 3 different thickness panels of AA2219 (0.95, 1.27 and 1.56 cm) at 2 different weld pitches. A bead on plate SR-FSW was also made in the 1.56 cm thick panel to understand the contribution of the former faying surfaces. Copper tracer studies were used to understand the flow lines associated with the weld tool used. The quality of the SR-FSWs was evaluated from tensile testing at room temperature. Reductions in the tensile strength were observed in some weldments, primarily at higher weld pitch or tool rotations. This study explores possible correlations between line defects and the reduction of strength in SR-FSWs. Results from this study will assist in a better understand of the mechanisms responsible for reduced tensile strength and provide methodology for minimizing their occurrence.

Schneider, Judy↗
NASA NTRS2017

Diamond-Dispersed Fiber-Reinforced Composite for Superior Friction and Wear Properties in Extreme Environments and Method for Fabricating the Same

Systems, methods, and articles of manufacture related to composite materials are discussed herein. These materials can be based on a mixture of diamond particles with a matrix and fibers or fabrics. The matrix can be formed into the composite material through optional pressurization and via heat treatment. These materials display exceptionally low friction coefficient and superior wear resistance in extreme environments.

Street, Kenneth↗
NASA NTRS2017

Microscopic Evaluation of Friction Plug Welds- Correlation to a Processing Analysis

Recently an analysis of dynamic forge load data from the friction plug weld (FPW) process and the corresponding tensile test results showed that good plug welds fit well within an analytically determined processing parameter box. There were, however, some outliers that compromised the predictions. Here the microstructure of the plug weld material is presented in view of the load analysis with the intent of further understanding the FPW process and how it is affected by the grain structure and subsequent mechanical properties.

Rabenberg, Ellen M.↗
NASA NTRS2018

Understanding Friction Stir Welding

This Technical Memorandum explains the friction stir welding process in terms of two basic concepts: the concentration of deformation in a shear surface enveloping the tool and the composition of the overall plastic flow field around the tool from simple flow field components. It is demonstrated how weld structure may be understood and torque, drag, and lateral tool forces may be estimated using these concepts. Some discrepancies between computations and accompanying empirical data are discussed in the text. This work is intended to be helpful to engineers in diagnosing problems and advancing technology.

Nunes, A. C., Jr.↗
NASA NTRS2018

Performance of Cassini Reaction Wheel Friction Compensation Scheme During Spin Rate Zero-Crossing and Drag Spikes

Cassini uses reaction wheels to achieve the spacecraft pointing stability that is needed during imaging operations of several science instruments. The Cassini flight software makes inflight estimates of reaction wheel bearing drag torque and the reaction wheel controller uses these estimates to achieve a high level of spacecraft pointing stability. However, the Cassini drag torque estimator was designed to accurately track the bearing drag torque only in the steady state. When the physical drag torque changes abruptly (for example, during a reaction wheel spin rate reversal or when wheel bearings experienced drag spikes), the drag estimator will not be able to track the physical drag closely. This will lead to a degradation in the spacecraft pointing stability performance. For Cassini, this was not a problem because of the significant performance margin in pointing stability. However, for missions that have very challenging pointing stability requirements and that must perform well in the presence of frequent wheel rate reversals, alternative drag-compensating control schemes must be considered. To this end, alternative drag torque compensating control schemes (such as the adaptive model reference control scheme) are briefly reviewed in this paper. Selected design features used in these friction compensation schemes may be incorporated in reaction wheel controller design to improve the robustness of spacecraft pointing stability performance with regard to a wide range of reaction wheel drag torque anomalous behavior.

Lee, Allan Y↗
DOE OSTI2013

Friction stir welding tool and process for welding dissimilar materials

A friction stir welding tool and process for lap welding dissimilar materials are detailed. The invention includes a cutter scribe that penetrates and extrudes a first material of a lap weld stack to a preselected depth and further cuts a second material to provide a beneficial geometry defined by a plurality of mechanically interlocking features. The tool backfills the interlocking features generating a lap weld across the length of the interface between the dissimilar materials that enhances the shear strength of the lap weld.

42 ENGINEERING↗
DOE OSTI2013

Joining of 14YWT and F82H by Friction Stir Welding

The feasibility of using friction stir welding (FSW) to join specimens of the advanced oxide dispersion strengthened (ODS) 14YWT nanostructured ferritic alloy (NFA) and a plate of F82H tempered martensitic steel (TMS) was investigated. The sample used in the FSW experiment consisted of spot welding four specimens 14YWT prepared from prior tested dual notch fracture toughness bend bars in a corresponding slot that was machined in the F82H plate. The FSW run was successfully performed on the sample using a polycrystalline boron nitride tool (PCBN) that resulted in joints showing good bonding between butt joints of 14YWT specimens and 14YWT specimens and F82H plate. The joints were characterized by light microscopy and SEM analysis and were observed to be relatively narrow in width. The ultra-fine grain size associated with 14YWT increased by a factor of up to 3 while that of F82H was refined by a considerable amount in the thermomechanically affected zones (TMAZ) due to FSW. In addition, porosity was observed in the TMAZ of 14YWT on the advancing side of the FSW joint and at the interface between F82H and 14YWT. Vickers hardness (VH) measurements showed a decrease of ~120 VH from ~500 VH (~20% decrease) for 14YWT and an increase of ~220 VH from ~220 VH (~100% increase) for F82H in the FSW zones. Further refinements in the FSW process will be required to minimize defects including porosity.

Hoelzer, David T↗
DOE OSTI2013

Energy conversion device and method of reducing friction therein

A device configured for converting energy includes a first surface, a second surface configured for moving with respect to the first surface during operation of the device, and a coating disposed on at least one of the first surface and the second surface. The coating includes a first layer of a ceramic alloy represented by the general formula AlMgB.sub.14--X, wherein X is present in an amount of from 0 to 70 parts by weight based on 100 parts by weight of the ceramic alloy and is a doping agent selected from the group of Group IV elements and borides and nitrides thereof, and a second layer disposed on the first layer and including carbon in a gradient concentration. The coating has a hardness of from 10 to 20 GPa and a coefficient of friction of less than or equal to 0.12.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2015

Study of Mechanical Properties and Characterization of Pipe Steel welded by Hybrid (Friction Stir Weld + Root Arc Weld) Approach

Friction stir welding (FSW) has recently attracted attention as an alternative construction process for gas/oil transportation applications due to advantages compared to fusion welding techniques. A significant advantage is the ability of FSW to weld the entire or nearly the entire wall thickness in a single pass, while fusion welding requires multiple passes. However, when FSW is applied to a pipe or tube geometry, an internal back support anvil is required to resist the plunging forces exerted during FSW. Unfortunately, it may not be convenient or economical to use internal backing support due to limited access for some applications. To overcome this issue, ExxonMobil recently developed a new concept, combining root arc welding and FSW. That is, a root arc weld is made prior to FSW that supports the normal loads associated with FSW. In the present work, mechanical properties of a FSW + root arc welded pipe steel are reported including microstructure and microhardness.

Lim, Yong Chae↗
DOE OSTI2017

Real-Time Measurement of Machine Efficiency during Inertia Friction Welding.

Process efficiency is a crucial parameter for inertia friction welding (IFW) that is largely unknown at the present time. A new method has been developed to determine the transient profile of the IFW process efficiency by comparing the workpiece torque used to heat and deform the joint region to the total torque. Particularly, the former is measured by a torque load cell attached to the non-rotating workpiece while the latter is calculated from the deceleration rate of flywheel rotation. The experimentally-measured process efficiency for IFW of AISI 1018 steel rods is validated independently by the upset length estimated from an analytical equation of heat balance and the flash profile calculated from a finite element based thermal stress model. The transient behaviors of torque and efficiency during IFW are discussed based on the energy loss to machine bearings and the bond formation at the joint interface.

42 ENGINEERING↗
DOE OSTI2016

Numerical modeling of heterogeneous asperity distributions controlling the growth of shear rupture on a frictional fault

Copyright 2016 ARMA, American Rock Mechanics Association. A better understanding of the strength distributions and the seismic response of asperities failing within a cohesive (or breakdown) region of the growing shear rupture is important in many engineering disciplines, such as, hydraulic fracture and induced seismicity. In the laboratory, a fault is experimentally modeled by a 400 mm × 80 mm × 12 mm PMMA slider sheared across a large PMMA base plate. A pressure-sensitive film was employed to localize and size, and measure normal stress upon contact junctions. Moments prior to rapid sliding, multiple discrete and localized dynamic events (or foreshocks) were observed at a section of the fault that exhibited a sparse to dense transition in asperity distribution. Experiments showed that foreshocks occurred as the crack (rupture front) moved into the resistive patch of densely distributed asperities. We use the results of pressure sensitive film asperity measurements to develop a heterogeneous finite element (FE) model that studies the effect of asperities within the cohesive region have on the expanding shear crack. Slip accumulated heterogeneously during the loading cycle due to the non-uniform distribution of asperities. We study the constitutive behavior of a frictional interface where local slip is determined by the asperities and their ability to communicate elastically. A foreshock (Mw -7.4) was simulated in a quasi-static manner by instantaneoulsy removing an asperity contact during the loading cycle. The foreshock increased shear stress perturbations to neighboring regions up to distances of ~ 10 to 15 source radii.

Selvadurai, PA↗
DOE OSTI2019

Friction stir welding bobbin tool

A bobbin tool is disclosed that includes a top shoulder, a bottom shoulder, and an axial pin that extends between the top and bottom shoulders. The bottom shoulder has an annular shoulder end surface, a back surface opposite the annular shoulder end surface, and a side surface that joins the annular shoulder end surface and the back surface. One or more and radially-extending blades may be disposed on the side surface of the bottom shoulder and/or one or more axially-extending blades may be disposed on the back surface. The one or more blades provide the bobbin tool with an ability to friction stir weld a variable thickness workpiece assembly, axially plunged through the workpiece assembly along an axis of rotation of the bobbin tool, and/or be extracted through the workpiece assembly along an axis of rotation of the bobbin tool.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

A FEASIBILITY STUDY ON CRACK REPAIR IN AUSTENITIC STAINLESS STEEL DRY STORAGE CANISTERS USING ISOTHERMAL FRICTION STIR WELDING

In recent time, solid state crack repair techniques in spent nuclear fuel dry storage canisters (SNF-DSC) have garnered significant interest. Plates of austenitic stainless steels are usually arc welded to fabricate the cylindrical canisters which are prone to chloride-induced stress corrosion cracking. Friction stir welding (FSW) is considered to be a potential candidate for damage repair. In this work, electrical discharge machining was used to simulate cracks in 304L stainless steel plates of 12.7 mm thickness. Subsequently, isothermal FSW was carried out at two different temperatures (725 and 825°C) in order to repair the simulated crack. Microstructure-mechanical property correlations in FSWed plates were studied in detail. Significant grain refinement observed in the stir zone (SZ) was attributed to dynamic recrystallization occurring during FSW. A comparison of Vickers microhardness showed higher hardness and homogeneity in the 725°C SZ than its 825°C counterpart. The fraction of S3 boundary is found to be low in the SZ as compared to base metal (BM). Yield strength of the joints was found to be approximately 100 MPa higher than that of the BM accompanied by a drop in ductility by a factor of 2. Residual stress profile across 825°C weld was measured using x-ray diffraction.

Bhattacharyya, Madhumanti↗
DOE OSTI2021

Turbine blade with friction and impact vibration damping elements

A turbine blade includes an airfoil body having an outer tip and a platform; and a part-span shroud positioned between the outer tip and the platform of the airfoil body. The part-span shroud has a first opening extending through the airfoil body and having a first inner surface. The airfoil body includes a second opening extending radially from the first opening and having a second inner surface. A first elongated vibration-damping element is disposed in the first opening, and a second elongated vibration-damping element disposed radially in the second opening. The second elongated vibration-damping element includes a free radially outer end and a radially inner end coupled to the first elongated vibration-damping element. The first elongated vibration-damping element frictionally damps vibration, and the second elongated vibration-damping element damps vibration using impact within the second opening.

Zhang, James↗
DOE OSTI2021

Friction testing and torque sensing systems

The present invention relates, in part, to systems for characterizing force (e.g., friction, wear, and/or torque). In one embodiment, the system allows for wear testing of samples in a high throughput manner. In another embodiment, the system allows for torque sensing in a non-contact manner.

Nation, Brendan L.↗
DOE OSTI2012

Heat transfer deterioration in tubes caused by bulk flow acceleration due to thermal and frictional influences

Severe deterioration of forced convection heat transfer can be encountered with compressible fluids flowing through strongly heated tubes of relatively small bore as the flow accelerates and turbulence is reduced because of the fluid density falling (as the temperature rises and the pressure falls due to thermal and frictional influence). The model presented here throws new light on how the dependence of density on both temperature and pressure can affect turbulence and heat transfer and it explains why the empirical equations currently available for calculating effectiveness of forced convection heat transfer under conditions of strong non-uniformity of fluid properties sometimes fail to reproduce observed behaviour. It provides a criterion for establishing the conditions under which such deterioration of heat transfer might be encountered and enables heat transfer coefficients to be determined when such deterioration occurs. The analysis presented here is for a gaseous fluid at normal pressure subjected strong non-uniformity of fluid properties by the application of large temperature differences. Thus the model leads to equations which describe deterioration of heat transfer in terms of familiar parameters such as Mach number, Reynolds number and Prandtl number. It is applicable to thermal power plant systems such as rocket engines, gas turbines and high temperature gas-cooled nuclear reactors. However, the ideas involved apply equally well to fluids at supercritical pressure. Impairment of heat transfer under such conditions has become a matter of growing interest with the active consideration now being given to advanced water-cooled nuclear reactors designed to operate at pressures above the critical value. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗