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DOE OSTI2021

QXF Cold Mass Friction Test

The purpose of this test is to determine the longitudinal force on the stainless steel shell that is required to break the friction between the stainless steel shell and the aluminum shell underneath. This is achieved by suspending the short magnet between two backing plates on the eight grade 8 threaded rods which replace the 8 stainless steel toke tie rods in the magnet assembly. Eight hydraulic cylinders are mounted to each backing plate. Six, 22" sections of the stainless steel shell are welded in place on the magnet, each of which has a slightly different developed length, starting from the baseline design, and becoming progressively looser. A pushing flange is mounted to the stainless steel shells via small tack welds. Four load cells are then attached to the flange at designated points, while additional tooling is attached to each of the cylinders to facilitate the transfer of force from the cylinders to the stainless steel shell During the test, the cylinders will be slowly energized to no more than 7000 psi, with a resultant, longitudinal force on the flange of no more than 125,400 lbf. For each set of shells, the test ends when the load cell monitoring software detects a sharp decrease in force. This will indicate that the friction has broken. The cullenders will then be de-energized and the cycle will repeat for the next test. Welding operations outlined in the procedure (US-HiLumi-doc-4200) are outside the scope of the HA as the work is occurring under a previously-issued burn permit by qualified welders.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Optimal white-noise stochastic forcing for linear models of turbulent channel flow

In the present study an optimisation problem is formulated to determine the forcing of an eddy-viscosity-based linearised Navier–Stokes model in channel flow at $Re_\tau \approx 5200$ ( $Re_\tau$ is the friction Reynolds number), where the forcing is white-in-time and spatially decorrelated. The objective functional is prescribed such that the forcing drives a response to best match a set of velocity spectra from direct numerical simulation (DNS), as well as remaining sufficiently smooth. Strong quantitative agreement is obtained between the velocity spectra from the linear model with optimal forcing and from DNS, but only qualitative agreement between the Reynolds shear stress co-spectra from the model and DNS. The forcing spectra exhibit a level of self-similarity, associated with the primary peak in the velocity spectra, but they also reveal a non-negligible amount of energy spent in phenomenologically mimicking the non-self-similar part of the velocity spectra associated with energy cascade. By exploiting linearity, the effect of the individual forcing components is assessed and the contributions from the Orr mechanism and the lift-up effect are also identified. Finally, the effect of the strength of the eddy viscosity on the optimisation performance is investigated. The inclusion of the eddy viscosity diffusion operator is shown to be essential in modelling of the near-wall features, while still allowing the forcing of the self-similar primary peak. In particular, reducing the strength of the eddy viscosity results in a considerable increase in the near-wall forcing of wall-parallel components.

Mechanics↗

NASA NTRS2017

Development and Testing of a Friction-Based Post-Installable Fiber-Optic Monitoring System for Subsea Applications

This paper presents the design and development of a friction-based coupling device for a fiber-optic monitoring system capable of measuring pressure, strain, and temperature that can be deployed on existing subsea structures. A summary is provided of the design concept, prototype development, prototype performance testing, and subsequent design refinements of the device. The results of laboratory testing of the first prototype performed at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) are also included. Limitations of the initial concept were identified during testing and future design improvements were proposed and later implemented. These new features enhance the coupling of the sensor device and improve the monitoring system measurement capabilities. A major challenge of a post-installed instrumentation monitoring system is to ensure adequate coupling between the instruments and the structure of interest for reliable measurements. Friction-based devices have the potential to overcome coupling limitations caused by marine growth and soil contamination on flowlines, risers, and other subsea structures. The work described in this paper investigates the design and test of a friction-based coupling device (herein referred to as a friction clamp) which is suitable for pipelines and structures that are suspended in the water column as well as for those that are resting on the seabed. The monitoring elements consist of fiberoptic sensors that are bonded to a stainless steel clamshell assembly with a high-friction surface coating. The friction clamp incorporates a single hinge design to facilitate installation of the clamp and dual rows of opposing fasteners to distribute the clamping force along the structure. The friction clamp can be modified to be installed by commercial divers in shallow depths or by remotely operated vehicles in deep-water applications. NASA-JSC was involved in the selection and testing of the friction coating, and in the design and testing of the prototype clamp device. Four-inch diameter and eight-inch diameter sub-scale friction clamp prototypes were built and tested to evaluate the strain measuring capabilities of the design under different loading scenarios. The testing revealed some limitations of the initial design concept, and subsequent refinements were explored to improve the measurement performance of the system. This study was part of a collaboration between NASA-JSC and Astro Technology Inc. within a study called Clear Gulf. The primary objective of the Clear Gulf study is to develop advanced instrumentation technologies that will improve operational safety and reduce the risk of hydrocarbon spillage. NASA provided unique insights, expansive test facilities, and technical expertise to advance technologies that will benefit the environment, the public, and commercial industries.

Bentley, Nicole L.↗

NASA NTRS1992

Alternative methods to model frictional contact surfaces using NASTRAN

Elongated (slotted) holes have been used extensively for the integration of equipment into Spacelab racks. In the past, this type of interface has been modeled assuming that there is not slippage between contact surfaces, or that there is no load transfer in the direction of the slot. Since the contact surfaces are bolted together, the contact friction provides a load path determined by the normal applied force (bolt preload) and the coefficient of friction. Three alternate methods that utilize spring elements, externally applied couples, and stress dependent elements are examined to model the contacted surfaces. Results of these methods are compared with results obtained from methods that use GAP elements and rigid elements.

Hoang, Joseph↗

NASA NTRS2017

Development and Testing of a Friction-Based Post-Installable Sensor for Subsea Fiber-Optic Monitoring Systems

This paper presents the design and development of a friction-based coupling device for a fiber-optic monitoring system that can be deployed on existing subsea structures. This paper provides a summary of the design concept, prototype development, prototype performance testing, and design refinements of the device. The results of the laboratory testing of the first prototype performed at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) are included in this paper. Limitations of the initial design were identified and future design improvements were proposed. These new features will enhance the coupling of the device and improve the monitoring system measurement capabilities. A major challenge of a post-installed instrumentation monitoring system is to ensure adequate coupling between the instruments and the structure of interest for reliable measurements. Friction-based coupling devices have the potential to overcome coupling limitations caused by marine growth and soil contamination on subsea structures, flowlines or risers. The work described in this paper investigates the design of a friction-based coupling device (friction clamp), which is applicable for pipelines and structures that are suspended in the water column and those that are resting on the seabed. The monitoring elements consist of fiber-optic sensors that are bonded to a metal clamshell with a high-friction coating. The friction clamp has a single hinge design to facilitate the operation of the clamp and dual rows of opposing fasteners to distribute the clamping force on the structure. The friction clamp can be installed by divers in shallow depths or by remotely operated vehicles in deep-water applications. NASA-JSC was involved in the selection and testing of the friction coating, and in the design and testing of the prototype clamp device. Four-inch diameter and eight-inch diameter sub-scale friction clamp prototypes were built and tested to evaluate the strain measuring capabilities of the design under different loading scenarios. The testing revealed some limitations of the initial design concept, and subsequent refinements were explored to improve the measurement performance of the system. This study was part of a collaboration between NASA-JSC and Astro Technology, Inc. within a study called Clear Gulf. The primary objective of the Clear Gulf study is to develop advanced instrumentation technologies that will improve operational safety and reduce the risk of hydrocarbon spillage. NASA provided unique insights, expansive test facilities, and technical expertise to advance these technologies that would benefit the environment, the public, and commercial industries.

Bentley, Nicole↗

NASA NTRS2017

Development and Testing of a Friction-Based Post-Installable Sensor for Subsea Fiber-Optic Monitoring System

Bentley, Nicole L.↗

DOE OSTI2023

Exploring ice sheet model sensitivity to ocean thermal forcing and basal sliding using the Community Ice Sheet Model (CISM)

Abstract. Multi-meter sea level rise (SLR) is thought to be possible within the next few centuries, with most of the uncertainty originating from the Antarctic land ice contribution. One source of uncertainty relates to the ice sheet model initialization. Since ice sheets have a long response time (compared to other Earth system components such as the atmosphere), ice sheet model initialization methods can have significant impacts on how the ice sheet responds to future forcings. To assess this, we generated 25 different ice sheet spin-ups, using the Community Ice Sheet Model (CISM) at a 4 km resolution. During each spin-up, we varied two key parameters known to impact the sensitivity of the ice sheet to future forcing: one related to the sensitivity of the ice shelf melt rate to ocean thermal forcing (TF) and the other related to the basal friction. The spin-ups all nudge toward observed thickness and enforce a no-advance calving criterion, such that all final spin-up states resemble observations but differ in their melt and friction parameter settings. Each spin-up was then forced with future ocean thermal forcings from 13 different CMIP6 models under the Shared Socioeconomic Pathway (SSP)5-8.5 emissions scenario and modern climatological surface mass balance data. Our results show that the effects of the ice sheet and ocean parameter settings used during the spin-up are capable of impacting multi-century future SLR predictions by as much as 2 m. By the end of this century, the effects of these choices are more modest, but still significant, with differences of up to 0.2 m of SLR. We have identified a combined ocean and ice parameter space that leads to widespread mass loss within 500 years (low friction and high melt rate sensitivity). To explore temperature thresholds, we also ran a synthetically forced CISM ensemble that is focused on the Amundsen region only. Given certain ocean and ice parameter choices, Amundsen mass loss can be triggered with thermal forcing anomalies between 1.5 and 2 ∘C relative to the spin-up. Our results emphasize the critical importance of considering ice sheet and ocean parameter choices during spin-up for SLR predictions and suggest the importance of including glacial isostatic adjustment in ice sheet simulations.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1983

Measurement of rolling friction by a damped oscillator

An experimental method for measuring rolling friction is proposed. The method is mechanically simple. It is based on an oscillator in a uniform magnetic field and does not involve any mechanical forces except for the measured friction. The measured pickup voltage is Fourier analyzed and yields the friction spectral response. The proposed experiment is not tailored for a particular case. Instead, various modes of operation, suitable to different experimental conditions, are discussed.

Dayan, M.↗

DOE OSTI2021

Atomistic observation on diffusion-mediated friction between single-asperity contacts

Super-lubricity, a sliding regime in which friction almost vanishes, has been well-documented with the advent of atomic force microscopy (AFM) and molecular dynamics (MD) simulation due to its enormous implications for manufacturing micro-/nano-electromechanical systems (MEMS/NEMS). Nevertheless, the atomistic mechanisms for super-lubricious behaviors are still elusive, primarily due to a lack of direct observation of interface at atomic resolution during frictional process. Here by using in situ high-resolution transmission electron microscopy (HRTEM) coupled with AFM, we report diffusion-mediated formation of a loosely-packed interfacial layer between two metallic asperities at infinitesimal normal forces, which is responsible for the sliding regime, super-lubricity exhibiting ultra-low friction forces and continuous sliding. By contrast, the loosely-packed interfacial layer vanishes along with the super-lubricity, leading to typical stick-slip friction. Additionally, in situ TEM observation and MD simulations reveals the crucial role that atom diffusion plays in atomic friction, and provides new insights into the fundamental mechanisms of super-lubricity.

42 ENGINEERING↗

DOE OSTI2022

Wedge-Shaped Hopper Design for Milled Woody Biomass Flow

The bioenergy industry has been challenged by unstable flow and transport of milled biomass in material handling operations. Handling issues such as hopper clogging and auger jamming are attributed to knowledge gaps between existing handling units designed for bulk solids and their suitability for milled biomass with high compressibility. This work investigates various flow behaviors of granular woody biomass in wedge-shaped hoppers. Herein, hopper flow physical experiments and numerical simulations are conducted to study the influence of the critical material attributes and critical processing parameters on the flow pattern, arching, and throughput. The results show that (1) the preferred flow pattern, mass flow, can be achieved by controlling the material’s internal friction angle, hopper inclination, and hopper wall friction; (2) hopper arching, governed by the competing gravity-driven force against flow resistance from material internal friction and material–wall friction, can be controlled by the hopper wall friction angle and the inclination angle; and (3) flow throughput can be accurately estimated from our empirical equation with inputs of hopper outlet geometry and particle-scale to bulk-scale material attributes. This study elucidates woody biomass flow physics and provides guidance for industrial equipment design.

09 BIOMASS FUELS↗

NASA NTRS2008

Gimballed Shoulders for Friction Stir Welding

In a proposed improvement of tooling for friction stir welding, gimballed shoulders would supplant shoulders that, heretofore, have been fixedly aligned with pins. The proposal is especially relevant to self-reacting friction stir welding. Some definitions of terms, recapitulated from related prior NASA Tech Briefs articles, are prerequisite to a meaningful description of the proposed improvement. In friction stir welding, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a pin that rotates with the shoulder and protrudes from the shoulder into the depth of the workpiece. In conventional friction stir welding, the main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional friction stir welding is augmented with an auto-adjustable pin-tool (APT) capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or forcecontrol system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding as practiced heretofore, there are two shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. Both shoulders rotate with the pin and remain aligned coaxially with the pin. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft into the friction-stir-welding machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. This concludes the prerequisite definitions of terms.

Carter, Robert↗

NASA NTRS2004

Mechanism for Self-Reacted Friction Stir Welding

A mechanism has been designed to apply the loads (the stirring and the resection forces and torques) in self-reacted friction stir welding. This mechanism differs somewhat from mechanisms used in conventional friction stir welding, as described below. The tooling needed to apply the large reaction loads in conventional friction stir welding can be complex. Self-reacted friction stir welding has become popular in the solid-state welding community as a means of reducing the complexity of tooling and to reduce costs. The main problems inherent in self-reacted friction stir welding originate in the high stresses encountered by the pin-and-shoulder assembly that produces the weld. The design of the present mechanism solves the problems. The mechanism includes a redesigned pin-and-shoulder assembly. The welding torque is transmitted into the welding pin by a square pin that fits into a square bushing with set-screws. The opposite or back shoulder is held in place by a Woodruff key and high-strength nut on a threaded shaft. The Woodruff key reacts the torque, while the nut reacts the tensile load on the shaft.

Venable, Richard↗

NASA NTRS1992

Validation and assimilation of Seasat altimeter wave heights using the WAM wave model

The third-generation wave model, WAM, is presently used to investigate the mutual consistency of the Seasat global data sets of scatterometer winds and altimeter wave heights for the complete Seasat period. While modeled and observed wave heights are in reasonable agreement on the global average, regional differences can be great and on occasion exceed 40 percent. These errors are primarily attributable to forcing wind field deficiencies; the friction velocities of the Goddard Laboratory for Atmospheres are found to be significantly underestimated in the high-wind belt of the Southern Hemisphere. A wave data assimilation scheme is presented in which the wave field is updated without change to the forcing wind field.

Bauer, Eva↗

NASA NTRS1983

Design of dry-friction dampers for turbine blades

A study is conducted of turbine blade forced response, where the blade has been modeled as a cantilever beam with a generally dry friction damper attached, and where the minimization of blade root strain as the excitation frequency is varied over a given range is the criterion for the evaluation of the effectiveness of the dry friction damper. Attempts are made to determine the location of the damper configuration best satisfying the design criterion, together with the best damping force (assuming that the damper location has been fixed). Results suggest that there need not be an optimal value for the damping force, or an optimal location for the dry friction damper, although there is a range of values which should be avoided.

Ancona, W.↗

NASA NTRS1996

Bending and Torsion Load Alleviator With Automatic Reset

A force transmitting load alleviator apparatus and method are provided for rotatably and pivotally driving a member to be protected against overload torsional and bending (moment) forces. The load alleviator includes at least one bias spring to resiliently bias cam followers and cam surfaces together and to maintain them in locked engagement unless a predetermined load is exceeded whereupon a center housing is pivotal or rotational with respect to a crown assembly. This pivotal and rotational movement results in frictional dissipation of the overload force by an energy dissipator. The energy dissipator can be provided to dissipate substantially more energy from the overload force than from the bias force that automatically resets the center housing and crown assembly to the normally fixed centered alignment. The torsional and bending (moment) overload levels can designed independently of each other.

delaFuente, Horacio M.↗

NASA NTRS2004

Auto-Adjustable Tool for Self-Reacting and Conventional Friction Stir Welding

A friction stir welding dcvice that is configured to perform convention friction stir welding as well as self-reacting friction stir welding is described. A pin passes hrough an upper shoulder and can selectively attach 10 and detach from a lower shoulder in a preferred embodiment. A controller maintains thc discrete position of, and/or force applied by, the upper and lower shoulders during self-reacting friction stir welding, or maintains the pin at a desired depth and/or applied force during conventional friction stir welding.

Robert W Carter↗

NASA NTRS2015

On the Effect of Rigid Swept Surface Waves on Turbulent Drag

Passive turbulent drag reduction techniques are of interest as a cost effective means to improve air vehicle fuel consumption. In the past, rigid surface waves slanted at an angle from the streamwise direction were deemed ineffective to reduce skin friction drag due to the pressure drag that they generate. A recent analysis seeking similarities to the spanwise shear stress generated by spatial Stokes layers suggested that there may be a range of wavelength, amplitude, and orientation in which the wavy surface would reduce turbulent drag. The present work explores, by experiments and Direct Numerical Simulations (DNS), the effect of swept wavy surfaces on skin friction and pressure drag. Plates with shallow and deep wave patterns were rapid-prototyped and tested using a drag balance in the 7x11 inch Low-Speed Wind Tunnel at the NASA LaRC Research Center. The measured drag o set between the wavy plates and the reference at plate is found to be within the experimental repeatability limit. Oil vapor flow measurements indicate a mean spanwise flow over the deep waves. The turbulent flow in channels with at walls, swept wavy walls and spatial Stokes spanwise velocity forcing was simulated at a friction Reynolds number of two hundred. The time-averaged and dynamic turbulent flow characteristics of the three channel types are compared. The drag obtained for the channel with shallow waves is slightly larger than for the at channel, within the range of the experiments. In the case of the large waves, the simulation over predicts the drag. The shortcomings of the Stokes layer analogy model for the estimation of the spanwise shear stress and drag are discussed.

Denison, M.↗

NASA NTRS1993

Mechanical energy absorber

An energy absorbing system for controlling the force where a moving object engages a stationary stop and where the system utilized telescopic tubular members, energy absorbing diaphragm elements, force regulating disc springs, and a return spring to return the telescoping member to its start position after stroking is presented. The energy absorbing system has frusto-conical diaphragm elements frictionally engaging the shaft and are opposed by a force regulating set of disc springs. In principle, this force feedback mechanism serves to keep the stroking load at a reasonable level even if the friction coefficient increases greatly. This force feedback device also serves to desensitize the singular and combined effects of manufacturing tolerances, sliding surface wear, temperature changes, dynamic effects, and lubricity.

Wesselski, Clarence J.↗