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NASA NTRS2008

Bonding and Integration Technologies for Silicon Carbide Based Injector Components

Advanced ceramic bonding and integration technologies play a critical role in the fabrication and application of silicon carbide based components for a number of aerospace and ground based applications. One such application is a lean direct injector for a turbine engine to achieve low NOx emissions. Ceramic to ceramic diffusion bonding and ceramic to metal brazing technologies are being developed for this injector application. For the diffusion bonding, titanium interlayers (PVD and foils) were used to aid in the joining of silicon carbide (SiC) substrates. The influence of such variables as surface finish, interlayer thickness (10, 20, and 50 microns), processing time and temperature, and cooling rates were investigated. Microprobe analysis was used to identify the phases in the bonded region. For bonds that were not fully reacted an intermediate phase, Ti5Si3Cx, formed that is thermally incompatible in its thermal expansion and caused thermal stresses and cracking during the processing cool-down. Thinner titanium interlayers and/or longer processing times resulted in stable and compatible phases that did not contribute to microcracking and resulted in an optimized microstructure. Tensile tests on the joined materials resulted in strengths of 13-28 MPa depending on the SiC substrate material. Non-destructive evaluation using ultrasonic immersion showed well formed bonds. For the joining technology of brazing Kovar fuel tubes to silicon carbide, preliminary development of the joining approach has begun. Various technical issues and requirements for the injector application are addressed.

Halbig, Michael C.↗

NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

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

Source record↗

NASA NTRS2019

The Legacy and Future of the International Earth Science Constellation (ESC)

The most recent Decadal Survey placed high value on continuing constellation science. The ESC has evolved by seeing new missions joining and old missions retiring. Most recently, GCOM-W1, Landsat-8, and OCO-2 joined during 2012-2014. Landsat-9 is set to join in 2020. Each new mission provides new and improved suite of sensors. The new sensors also benefit both from the multitude of other existing on-orbit sensors as well as from the long-term cross-calibrated climate observations from the sensors that preceded them. At the same time, existing missions leave the constellation due to low fuel reserves or aging spacecraft subsystems. For example, CloudSat and CALIPSO left the ESC orbits in 2018, although they plan to continue making coordinated science observations at their new lower altitudes. This ESC evolution is expected to continue and this paper will discuss the opportunities for other new missions to join the ESC.

afternoon constellation↗

NASA NTRSDate not supplied

An Evening with NASA Scientists and Engineers: A Senior Living Community Outreach Program

Introduction: An Evening with NASA Scientists and Engineers is an outreach program for senior living communities, where participants learn from and interact with a scientist or engineer in a virtual setting. Participants learn about NASA science and engineering through a behind-the-scenes look from the people who work at NASA. The program focuses on both the stories behind the discoveries and the stories behind the people. The audience tunes in to the events via the NASA Zoom Webinar platform, where they have the opportunity to ask questions throughout the approximately 30-minute program. By bringing the audience into the conversation, we build rapport and thus improve their connection with NASA. Overview: An Evening with NASA Scientists and Engineers began in September 2020 when we identified a need for outreach to this particular demographic, as senior living communities had been hit especially hard by the COVID-19 pandemic. The program covers a wide range of topics, including heliophysics, astrophysics, planetary science, Earth science, planetary defense, and more, depending on what is topically appropriate at the time, and occurs on a roughly monthly basis. Each interactive presentation is between 20-25 minutes with 5-10 minutes of dedicated Q&A. Future dates and topics may change depending on new developments to NASA missions and stories. Audience: As of December 2021, we have four regularly attending senior living communities, spanning the East Coast from New Hampshire to Florida, with each joining the overall program at various stages of its development. The ability to reach many different senior living communities is crucial so that a diversity of people may benefit from this program. The audience consists of seniors with varying experience and comprehension levels – some are very familiar with the sciences while others are simply curious to learn more. Residents tune in to each event from their individual rooms or from their larger community rooms. RiverWoods Exeter. The RiverWoods Exeter community was our initial audience who acted as our “guinea pig” to see how this program might be implemented and to work out any major issues. They are located in Exeter, NH but also have two additional campuses in Durham, NH and Manchester, NH, that joined us a few months into the program. Culpepper Garden. Our second community to join the program was Culpepper Garden, a senior living community in Arlington, VA that provides both independent and assisted living housing to low-income seniors. Edinburgh Square. Our third community, Edinburgh Square, connected with us after hearing about the program through Culpepper Garden. Edinburgh Square is an HUD-subsidized retirement community in Roanoke, VA that houses both seniors and those living with disabilities. Moonstruck Astronomy Club. The Moonstruck Astronomy Club consists of residents from the On Top of the World retirement community in Ocala, FL and was the latest senior living community to join us. NASA Zoom Webinar: An Evening with NASA Scientists and Engineers reaches numerous senior living communities through live presentations that we host using the NASA Zoom Webinar virtual platform. Participants are typically already familiar with the Zoom platform which enables a lower barrier to entry. A recording of each talk is added to a designated video playlist on the NASA STEM YouTube channel so that audiences worldwide may view them [1]. These recordings began with our April 1, 2021 presentation, as this was when NASA Zoom Webinar was implemented, thus enabling us to record each talk. Metrics: We record attendance numbers from the senior living communities for each event as well as those from YouTube views after the presentation recording is posted online. Depending on which communities tune in, typical attendance numbers are between 60-100 people. RiverWoods Exeter has the most regularly attending residents, with an average of 55 attendees per event. As of December 2021, we have hosted fourteen events, nine of which were recorded and posted to our designated NASA STEM YouTube Channel playlist. The nine recordings combined have roughly 4,000 YouTube views thus far, with specific videos seeing higher view counts around launch dates (e.g. NASA’s DART mission) and trending topics (e.g. JWST). A list of speakers, topics, and links to presentation recordings is shown in Table 1. Future Program Expansion: Thus far, we have been adding communities on an individual basis. To make this process more streamlined, we are looking into working with senior living community networks and organizations such as LeadingAge [2]. In this manner, we will be able to reach more communities while also making it easier to send and receive relevant information.

S L Tiedeken↗

DOE OSTI2024

Mitigation of distortion of Al/steel part under simulated paint baking condition: Experiment and numerical model studies

Multi-material joining of lightweight structures is essential to reduce vehicle weight for more energy savings and less greenhouse gas emission. However, mismatch of thermal expansion coefficient for dissimilar materials during the paint baking process can induce part distortion and joint failure for adhesive bonding. Here, in the present work, a thermomechanical model based on contact mechanics and large deformation theory was developed for dissimilar high-strength Al alloy and steel components to study the distortion mechanism and influential factors of the residual gap. The established model was used to optimize joint conditions, such as pitch distance and part geometry. When a weld pitch is shorter than 100 mm, the maximum gap between Al and steel part can be greatly reduced to 0.1 mm, and the local stress and plastic strain around the joint during the oven heating and cooling cycle are also substantially reduced compared with the long pitch case (900 mm). The numerical modeling results revealed that a comparable bending stiffness ratio between the steel and Al cross sections is critical to the minimization of gap and distortion under paint baking condition. Digital image correlation technique was used to measure the overall part distortion and local strain distribution that were used to validate the model prediction. Weld bonding (adhesive bonding with friction bit joining) process was successfully employed to join Al to steel component without gap opening in adhesive after the paint baking and cooling.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Welding in Space: Past, Present, and Future

It has been over fifty years since the first welds were made in space by Soviet cosmonauts on Soyuz-6 in October of 1969. The United States performed bead-on-plate welding, brazing, and metal melting experiments onboard the Skylab orbital space station several years later in 1973. Finally, Soviet cosmonauts departed their Salyut-7 capsule and made the first (and last) welds in open space in 1984. Progress on further demonstrations of welding in space stagnated, and subsequent microgravity welding research work shifted to lower-cost earth-based experiments that include drop towers and parabolic flights. With the advent of the International Space Station, relevant microgravity research was undertaken in the field of metal solidification science, and limited studies of brazing and soldering were undertaken; however, no welds have ever been on the Space Station. Therefore, it has been almost 40 years since a weld was made in space. Much like terrestrial construction and manufacturing industries, welding, joining, and allied processes will be enabling technologies for In-space Assembly and Manufacturing (ISAM) in the nascent “Space Economy”, a sector that is expected to approach a value of 10^12 USD within the next decade. It is critical that the welding and joining research community, along with the welding industry, engages the space industry to advance the understanding of those critical manufacturing processes which must be evaluated and matured in the extreme environments of space. Such environments include variable gravity (microgravity in low earth orbit, 0.17 gravity on the lunar surface, and 0.38 gravity on the martian surface), reduced pressure (extreme vacuum in space and the lunar surface to a predominantly CO2 atmosphere on Mars), and extreme temperatures (between 40 and 400 K). Past experiments and analyses are reviewed to suggest requirements that the welding and joining community should target to make strides on closing the current space welding gaps. Efforts to continue welding in space are currently underway at NASA in conjunction with academia and industry. Those are explored along with future agency goals which are seen as opportunities to engage the welding community on this historic effort.

in-space assembly and manufacturing↗

DOE OSTI2026

Multi-Objective design of interlocking metasurfaces using conditional diffusion models

Unit cell design remains a major challenge for interlocking metasurfaces, a promising joining technology for dissimilar materials, due to the complex, competing, multivariate design space and the need for rapid adaptation to varying performance requirements. This study explores Conditional Diffusion Models as a design optimization tool for interlocking metasurfaces. Given the complex, competing, multivariate design space for interlocking metasurfaces, unit cell design remains a major challenge for this joining technology. We trained a conditional diffusion model on 25,000 finite element analysis-simulated interlocking metasurface unit cells to generate designs with tailored thermo-mechanical properties (tensile strength, shear strength, and thermal conductivity) based on specified performance criteria. The model demonstrated a success rate of approximately 72 % in producing designs that met specified property bounds. The conditional diffusion model generated both thermally resistive and conductive designs, revealing clear trends in design characteristics: taller, dendritic structures were advantageous for tensile loads, while shorter, robust designs excelled in shear applications. Our findings indicate that the model's performance is more influenced by the breadth of the design space than by the quantity of training data, highlighting the importance of expansive design domains for generating innovative solutions. This work establishes conditional diffusion models as a highly efficient and adaptable tool for rapid interlocking metasurface unit cell design, paving the way for advancements in multi-material joining technologies, as well as highlighting the justification to leverage conditional diffusion models as design tools across complex design domains.

Conditional diffusion models↗

DOE OSTI2026

Correlation between microstructure and residual stress formation in friction stir welded armor steels characterized by neutron diffraction

Friction stir welding (FSW) is a solid-state joining process that minimizes the heat-affected zone (HAZ) compared with fusion-based arc welding, making it well suited for joining martensitic armor steels where hardness and ballistic resistance are critical. This study investigates residual stress formation in three defect-free FSW butt-joint configurations relevant to armored-vehicle fabrication: similar rolled homogeneous armor (RHA–RHA, Case 1), similar high-hardness armor (HHA–HHA, Case 2), and dissimilar HHA–RHA (Case 3) joints produced under temperature-controlled conditions (770 °C). Neutron diffraction was employed to quantify the magnitude and spatial distribution of residual stresses in the longitudinal, transverse, and normal directions and to correlate them with weld microstructure and hardness. Tensile residual stresses were concentrated in the softened HAZ, reaching approximately 300 MPa for Case 2 and 400 MPa for Case 1 (≈50–70 % of the base-metal yield strength; ∼581 MPa for RHA and ∼566 MPa for HHA), while compressive residual stresses dominated the stir zone. The spatial extent of tensile stresses scaled with the width of the softened HAZ, which was largest in the dissimilar HHA–RHA joint and smallest in the HHA–HHA joint. Full-width-at-half-maximum (FWHM) analysis revealed low microstrain in overtempered HAZ regions and high microstrain in the stir zone associated with severe plastic deformation and fresh martensite formation. This work demonstrates that residual stress evolution in FSW of martensitic armor steels is governed not primarily by peak temperature or thermal contraction, as inferred from fusion-welding analogies, but by the competition between transformation-induced volumetric expansion and tempering-induced stress relaxation. The relative dominance of these mechanisms is shown to depend on alloy hardenability and local thermal history, leading to more extensive HAZ softening and broader tensile stress regions in the lower-hardenability RHA steel. These findings establish a transferable mechanistic framework for optimizing solid-state joining strategies in high-strength steels and other transformation-hardening alloys beyond armor applications.

Friction stir welding↗

DOE OSTI2025

BAMCensus (The Behavior and Advanced Mobility Census Dataset Aggregator) [SWR-25-120]

This software is a high-performance tool developed in Rust for downloading and processing large-scale geospatial datasets, specifically focusing on US Census data. It is designed to address scaling limitations found in existing tools, such as R's [tidycensus](https://walker-data.com/tidycensus/), by providing performant streaming dataset JOIN operations between various US Census datasets (like ACS and LEHD) and their corresponding geometries stored on the TIGER/Lines web server. The tool automates the process of joining these data sources, returning aggregated data to the user based on a specified census GEOID type. The tool automates the process of joining these data sources, returning aggregated data to the user based on a specified census GEOID type. Its primary motivation stems from the need for a high-performance solution to combine spatial datasets with graph traversals within the context of mobility analysis tooling being developed at NREL's Behavior and Advanced Mobility (BAM) group.

Fitzgerald, Robert [National Renewable Energy Labo↗

NASA NTRS1972

Development of dispersion-strengthened Ni-Cr-ThO2 alloys for the space shuttle thermal protection system.

An improved manufacturing process has been developed for TD-NiCr that provides sheet of improved quality, better gage control, and reproducible properties. A standard manufacturing process has been developed for the alternate alloy, DS-NiCr, produced by pack-chromizing Ni-2ThO2 sheet. Extension of forming and joining technology for TD-NiCr is in process. Formability criteria are being established for basic sheet forming processes related to the manufacture of Shuttle TPS panels. They include brake forming, corrugation forming, joggling, dimpling, and beading. Joining processes applicable to TPS panels are being optimized with emphasis on establishment of joint efficiencies. Resistance spot welding (fusion and solid state), resistance seam welding, solid-state diffusion welding, and brazing are included in the joining programs. Development of improved manufacturing technology for TD-NiCr fasteners is also being accomplished. Mechanical and physical properties of TD-NiCr are being characterized to provide design-allowable data.

Blankenship, C. P.↗

NASA NTRS1973

Self-adjusting assembly jig

Jig adjusts for thermal expansion and contraction to hold parts being joined under constant pressure and in correct alignment during entire joining operation. Jig is simple and easy to use, durable and maintenance free. Several methods may be used to join parts of many sizes and shapes.

Haaser, M. J.↗

NASA NTRS1973

Radial honeycomb core

Core alleviates many limitations of conventional nacelle construction methods. Radical core, made of metals or nonmetals, is fabricated either by joining nodes and then expanding, or by performing each layer and then joining nodes. Core may also be produced from ribbons or strips with joined nodes or ribbons oriented in longitudinal planes.

Cantley, R. B.↗

NASA NTRS1976

Compound solder joints

Joining technique prevents contamination, may be used to join dissimilar metal tubes, minimizes fluid and gas entrapment, expedites repairs, and can yield joints having leakage rates less than 0.000001 standard cubic cm He/min. Components of joint are solder sleeve, two solder rings, Teflon sleeve, and tubing to be joined.

Batista, R. I.↗

NASA NTRS1981

Reusable captive blind fastener

A one piece reusable fastener capable of joining materials together from one side (blind backside) comprises a screw driven pin ending in a wedge-shaped expander cone. The cone cooperates within a slotted collar end which has a number of tangs on a cylindrical body. The fastener is set by inserting it through aligned holes in the workpieces to be joined. Turning the pin in one direction draws the cone into the collar, deforming the tangs radially outward to mate with tapered back-tapered hold in the workpiece, thus fastening the two pieces together. Reversing the direction of the pin withdraws the cone from the collar, and allows the tangs to resume their contracted configuration without withdrawing the fastener from the insertion hole. The fastener is capable of joining materials together from only one side with substantial strength in tension and shear over many resue attachment cycles, with no special operations on the main assembly parts other than the tapering of the back end of the insertion hole.

Peterson, S. A.↗

NASA NTRS1983

Practical small-scale explosive seam welding

A small-scale explosive seam welding process has been developed that can significantly contribute to remote metal joining operations under hazardous or inaccessible conditions, such as nuclear reactor repair and assembly of structure in space. This paper describes this explosive seam welding process in terms of joining principles, variables, types of joints created, capabilities, and applications. Very small quantities of explosive in a ribbon configuration are used to create narrow (less than 0.5 inch), long-length, uniform, hermetically sealed joints that exhibit parent metal properties in a wide variety of metals, alloys, and combinations. The practicality of this process has been demonstrated by its current acceptance, as well as its capabilities that are superior in many applications to the universally accepted joining processes, such as mechanical fasteners, fusion and resistance welding, and adhesives.

Bement, L. J.↗

NASA NTRS1983

Practical small-scale explosive seam welding

Bement, L. J.↗

NASA NTRS1985

Derivation and test of elevated temperature thermal-stress-free fastener concept

Future aerospace vehicles must withstand high temperatures and be able to function over a wide temperature range. New composite materials are being developed for use in designing high-temperature lightweight structures. Due to the difference between coefficients of thermal expansion for the new composite materials and conventional high-temperature metallic fasteners, innovative joining techniques are needed to produce tight joints at all temperatures without excessive thermal stresses. A thermal-stress-free fastening technique is presented that can be used to provide structurally tight joints at all temperatures even when the fastener and joined materials have different coefficients of thermal expansion. The derivation of thermal-stress-free fasteners and joint shapes is presented for a wide variety of fastener materials and materials being joined together. Approximations to the thermal-stress-free shapes that result in joints with low-thermal-stresses and that simplify the fastener/joint shape are discussed. The low-thermal-stress fastener concept is verified by thermal and shear tests in joints using oxide-dispersion-strengthened alloy fasteners in carbon-carbon material. The test results show no evidence of thermal stress damage for temperatures up to 2000 F and the resulting joints carried shear loads at room temperature typical of those for conventional joints.

Sawyer, J. W.↗

NASA NTRS1990

Kinetics and thermodynamics of ceramic/metal interface reactions related to high T(sub c) superconducting applications

Superconducting ceramic materials, no matter what their form, size or shape, must eventually make contact with non-superconducting materials in order to accomplish current transfer to other parts of a real operating system, or for testing and measurement of properties. Thus, whether the configuration is a clad wire, a bulk superconducting disc, tape, or a thick or thin superconducting film on a substrate, the physical and mechanical behavior of interface (interconnections, joints, etc.) between superconductors and normal conductor materials of all kinds is of extreme importance to the technological development of these systems. Fabrication heat treatments associated with the particular joining process allow possible reactions between the superconducting ceramic and the contact to occur, and consequently influence properties at the interface region. The nature of these reactions is therefore of great broad interest, as these may be a primary determinant for the real capability of these materials. Research related both to fabrication of composite sheathed wire products, and the joining contacts for physical property measurements, as well as, a review of other related literature in the field are described. Comparison are made between 1-2-3, Bi-, and Tl-based ceramic superconductors joined to a variety of metals including Cu, Ni, Fe, Cr, Ag, Ag-Pd, Au, In, and Ga. The morphology of reaction products and the nature of interface degradation as a function of time will be highlighted.

Notis, Michael R.↗