Search NASA⌕ Search

SEARCH · Search NASA

Results for “Joint strength”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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

At least 37 records · Page 2

Exploring Failure of Adhesively-Bonded Joints with Different Void Sizes at the Same Void Volume Fraction through A Micro-scale Numerical Modeling

This paper studied the effects of void sizes on the failure behavior of adhesively-bonded materials under global shear via micro-scale computational modeling. The numerical results indicate that large void sizes with increased distances between them at the same void volume fraction can alleviate the reduced joint strength of a weaker adherend-adhesive interface caused by interfacial voids. However, this is not the case for an adherend-adhesive interface with the interfacial tensile strength being sufficiently higher than the adhesive strength, showing the negligible effect on the joint strength due to various void sizes and the amount of interfacial voids. This preliminary investigation provides insightful information for scaling up the void size in the macro-scale computational modeling of joints, and enhances the understanding of the micro-mechanical adhesion in adherend-adhesive interfaces with different levels of bonding.

Qiao, Yao↗

Improved stud configurations for attaching laminated wood wind turbine blades

A series of bonded stud design configurations was screened on the basis of tension-tension cyclic tests to determine the structural capability of each configuration for joining a laminated wood structure (wind turbine blade) to a steel flange (wind turbine hub). Design parameters which affected the joint strength (ultimate and fatigue) were systematically varied and evaluated through appropriate testing. Two designs showing the most promise were used to fabricate addiate testing. Two designs showing the most promise were used to fabricate additional test specimens to determine ultimate strength and fatigue curves. Test results for the bonded stud designs demonstrated that joint strengths approaching the 10,000 to 12,000 psi ultimate strength and 5000 psi high cycle fatigue strength of the wood epoxy composite could be achieved.

Fadoul, J. R.↗

Analysis of bolt-loaded elliptical holes in laminated composite joints

The feasibility of changing the bolt shape from circular to elliptical in order to increase the joint strength was investigated. An analytical method using a cosine series to represent the bearing stress was derived, and a boundary collocation method was used to determine the unknown coefficients of this cosine series. Stresses at the hole edge predicted by the analytical method agreed very well with finite element solutions. Failure analyses of joints in two different laminates were performed, and each laminate exhibited a different joint failure mode. Results demonstrate that the joint strength of both laminates can be improved substantially by changing the bolt shape to elliptical. The joint that failed in a bearing mode showed a greater strength increase compared to the joint that failed in a shearing mode.

Wang, J. T.↗

Diffusion welding of Cassegrainian concentrator cell stack assemblies

Development of a procedure to join the components of the Cassegrainian concentrator photovoltaic cell stack assembly was studied. Diffusion welding was selected as the most promising process, and was concentrated on exclusively. All faying surfaces were coated with silver to promote welding. The first phase of the study consisted of developing the relationship between process parameters and joint strength using silver plated steel samples and an isostatic pressure system. In the second phase, mockups of the cell stack assembly were welded in a hot isostatic press. Excellent joint strength was achieved with parameters of 350 C and 10 ksi, but the delicate GaAs component could not survive the welding cycle without cracking. The tendency towards cracking was found to be affected by both temperature and pressure. Further work will be required in the future to solve this problem.

Gangl, K. J.↗

Sources of Uncertainty in Ultrasonic Phase-Based Assessment of Interfacial Stiffness in Adhesive Joints

Quantitative nondestructive evaluation (NDE) of adhesive joint strength is critical for certifying fastener-free bonded aerospace structures. Unfortunately, available adhesive NDE approaches are only suitable for detecting gross defects and delamination and cannot reliably detect variations in strength in intact bonds. Intact (i.e., nominally defect free) bonds are challenging to inspect because they, by definition, contain no macroscopic defects that would produce a strong NDE signature. Even in the absence of obvious defects, however, bond strength can vary substantially due to factors such as contamination, variations in the adhesive cure processes, and environmental exposure. For ultrasonic bond inspections, the effect of interactions from an imperfect adhesive interface are subtle and may include changes in the frequency content or phase of the ultrasonic signal. The bond condition can be deduced from these subtle changes in the acoustic response using an accompanying physics-based model of adhesive joint interaction. For example, researchers have used the spring network adhesion model of Baik and Thompson [1] to determine the interfacial stiffness of the joint from its ultrasonic response (e.g., [2]). This interfacial stiffness metric describes the bonds resistance to separation between the adhesive and adherent and has shown a strong correlation with joint strength. In this study, interfacial stiffness is assessed using the ultrasonic phase change associated with bond interaction in varying bond conditions. The phase change is measured precisely using a phase-locked-loop instrument over a swept range of frequencies. The phase transition at resonance, where the bond thickness is half the acoustic wavelength, produces a unique signature with which to fit a physics-based model. Interfacial stiffness is determined by minimizing the difference between the theoretical and experimental phase response. Experimental results are presented for glass specimens bonded with aerospace adhesives and a sensitivity analysis is performed to examine the effects of parameters that may be uncertain in the industrial inspection environment – namely bond thickness, adhesive and adherent properties, and porosity. The results are a first step toward an uncertainty quantified version of the measurement technique, show correlation between interfacial stiffness and bond strength, and are another key step toward maturing this approach for use in complex materials and joint geometries. [1] Baik, J.M. and Thompson, R.B., 1984. “Ultrasonic scattering from imperfect interfaces: a quasi-static model”. Journal of Nondestructive Evaluation, 4. [2] Haldren, H.A., Perey, D.F., Yost, W.T., Cramer, K.E., and Gupta, M.C., 2019. “Swept-frequency ultrasonic phase evaluation of adhesive bonding in tri-layer structures”. Journal of the Acoustical Society of America, 145.

Matt Webster↗

Current-Activated Reactive Ultrafast Joining (CARUJ)

We have demonstrated Current Activated Reactive Ultrafast Joining (CARUJ) as a novel approach for rapid fabrication of similar and dissimilar materials, such as ceramic-ceramic and ceramic-metal joint assemblies. The CARUJ technology utilizes resistive heating of carbon-based materials to apply localized heat at, (through or around) joint zones at rates of 10 1 -10 2 ˚C/min, enabling joining at time scales considerably shorter (several minutes as opposed to hours) than conventional approaches for similar systems. Herein, we present our findings while evaluating the CARUJ concept. Three methods of heat application were evaluated: (i) using carbon joule heating elements to apply heat directly through the joint interface; (ii) using flexible joule heating elements to locally apply heat around the assembly interface; and (iii) non-contact heating of the joint assembly using inductive power. Schemes (ii) and (iii) proved to be the most effective in producing mechanically sound reliable joints. We demonstrated single-step fabrication of dense SiC-SiC joints with a Si- SiC interface using minimal pressure (1–2 MPa) in under 30 minutes. Measured average joint strengths of about 15 MPa are initially achieved for joined bodies when tested in single lap offset (SLO) compressive shear, while tuning of the interfacial composition along with a reduction in interlayer thickness, results in improved joint strengths of approximately 43 MPa. We further demonstrated SiC-SiC joining using Active Brazing Alloys (ABAs) proof of concept joining of tubular geometries. The versatility of CARUJ is demonstrated by utilizing non-contact heating via induction, to join dissimilar materials systems of SiC, SS316 and MAX phase ceramics with ABA interlayers. The localized and rapid heat application realizes a versatile material joining technique that can be extended for joining components at the plant site.

36 MATERIALS SCIENCE↗

Aerospace Threaded Fastener Strength With Joint Shims

Bolted joints with a nonload-carrying member, like a shim or spacer, and loaded in shear introduce bending moment into the bolt that reduces the bolt shear load-carrying capability. Various design criteria are available that attempt to account for the additional bending and provide reduced allowable bolt loads. The actual shear load-carrying capability of a typical aerospace fastener with various thickness shims was determined by test using both aluminum and steel joint members. The results are compared against existing design criteria, which are shown to be adequate for their intended purposes.

threaded fastener, bolt, strength criteria, shim, ↗

Effects of porosity on weld-joint tensile strength of aluminum alloys

Tensile properties in defect-free weldments of aluminum alloys 2014-T6 and 2219-T87 (sheet and plate) are shown to be related to the level or concentration of induced simulated porosity. The scatter diagram shows that the ultimate tensile strength of the weldments displays the most pronounced linear relationship with the level of porosity. The relationships between yield strength or elongation and porosity are either trivial or inconsequential in the lower and intermediate levels of porosity content. In highly concentrated levels of porosity, both yield strength and elongation values decrease markedly. Correlation coefficients were obtained by simple straight line regression analysis between the variables of ultimate tensile strength and pore level. The coefficients were greater, indicating a better correlation, using a pore area accumulation concept or pore volume accumulation than the accumulation of the pore diameters. These relationships provide a useful tool for assessing the existing aerospace radiographic acceptance standards with respect to permissible porosity. In addition, these relationships, in combination with known design load requirements, will serve as an engineering guideline in determining when a weld repair is necessary based on accumulative pore level as detected by radiographic techniques.

Lovoy, C. V.↗

Strength Variation of Parachute Joints

A parachute joint is defined as a location where a component is sewn or connected to another component. During the design and developmental phase of a parachute system, the joints for each structural component are isolated and tested through a process called seam and joint testing. The objective of seam and joint testing is to determine the degradation on a single component due to interaction with other components; this data is then used when calculating the margin of safety for that component. During the engineering developmental phase of CPAS (Capsule Parachute Assembly System), the parachute system for the NASA Orion Crew Module, testing was completed for every joint of the six subsystems: the four parachutes (main, drogue, pilot, and FBCP [forward bay cover parachute]), the retention release bridle, and the retention panels. The number of joint tests for these subsystems totaled 92, which provides a plethora of data and results for further analysis. In this paper, the data and results of these seam and joint tests are examined to determine the effects, if any, of different operators and sewing machines on the strength of parachute joints. Other variables are also studied to determine their effect on joint strength, such as joint complexity, joint strength magnitude, material type, and material construction. Findings reveal that an optimally-run seam and joint test program could result in an increased understanding of the structure of the parachute; this should lead to a parachute built with optimal components, potentially saving system weight and volume.

Mollmann, Catherine↗

Active Metal Brazing and Characterization of Brazed Joints in Titanium to Carbon-Carbon Composites

The Ti-metal/C-C composite joints were formed by reactive brazing with three commercial brazes, namely, Cu-ABA, TiCuNi, and TiCuSiI. The joint microstructures were examined using optical microscopy and scanning electron microscopy (SEM) coupled with energy dispersive spectrometry (EDS). The results of the microstructure analysis indicate solute redistribution across the joint and possible metallurgical bond formation via interdiffusion, which led to good wetting and spreading. A tube-on-plate tensile test was used to evaluate joint strength of Ti-tube/ C-C composite joints. The load-carrying ability was greatest for the Cu-ABA braze joint structures. This system appeared to have the best braze spreading which resulted in a larger braze/C-C composite bonded area compared to the other two braze materials. Also, joint loadcarrying ability was found to be higher for joint structures where the fiber tows in the outer ply of the C-C composite were aligned perpendicular to the tube axis when compared to the case where fiber tows were aligned parallel to the tube axis.

Singh, M.↗

Shear joint capability versus bolt clearance

The results of a conservative analysis approach into the determination of shear joint strength capability for typical space-flight hardware as a function of the bolt-hole clearance specified in the design are presented. These joints are comprised of high-strength steel fasteners and abutments constructed of aluminum alloys familiar to the aerospace industry. A general analytical expression was first arrived at which relates bolt-hole clearance to the bolt shear load required to place all joint fasteners into a shear transferring position. Extension of this work allowed the analytical development of joint load capability as a function of the number of fasteners, shear strength of the bolt, bolt-hole clearance, and the desired factor of safety. Analysis results clearly indicate that a typical space-flight hardware joint can withstand significant loading when less than ideal bolt hole clearances are used in the design.

Lee, H. M.↗

Explosive Welding for Remote Applications

Explosive seam welding produces up to 100-percent joint strength. Ribbon explosive activated by remote energy source produces metallurgically sound joint. Success of technique verified for joints between like metals and joints between two different metals. Applications include structural assembly in toxic atmospheres and in radioactive or otherwise hazardous environments.

Bement, L. J.↗

Microhardness and Strain Field Characterization of Self-Reacting Friction Stir and Plug Welds of Dissimilar Aluminum Alloys

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. This work reports on material properties and strain patterns developed in a SR-FSW with a friction plug weld. Specifically, this study examines the behavior of a SR-FSW formed between an AA 2014-T6 plate on the advancing side and an AA 2219-T87 plate on the retreating side and a SR-FSW (AA 2014-T6 to AA 2219-T87) with a 2219-T87 plug weld. This study presents the results of a characterization of the micro-hardness, joint strength, and strain field characterization of SR-FSW and FPW joints tested at room temperature and cryogenic temperatures.

Horton, Karla Renee↗

Weld geometry strength effect in 2219-T87 aluminum

A theory of the effect of geometry on the mechanical properties of a butt weld joint is worked out based upon the soft interlayer weld model. Tensile tests of 45 TIG butt welds and 6 EB beads-on-plate in 1/4-in. 2219-T87 aluminum plate made under a wide range of heat sink and power input conditions are analyzed using this theory. The analysis indicates that purely geometrical effects dominate in determining variations in weld joint strength with heat sink and power input. Variations in weld dimensions with cooling rate are significant as well as with power input. Weld size is suggested as a better indicator of the condition of a weld joint than energy input.

Nunes, A. C., Jr.↗

Scale-Up of Friction Self-piercing Riveting Process for Multi-material Joints

A single-class joining process known as “friction self-piercing riveting (F-SPR)” has been developed for joining various low-ductility lightweight materials on a laboratory scale. The frictional heat generated during the F-SPR process improved local ductility, resulting in crack-free joints and robust mechanical performance. This innovative joining technology was further advanced through the scale-up of the process using a new system with several key features (e.g., automatic rivet feeding and clamping system, vacuum system) toward industry readiness. The new integrated F-SPR systems were effectively demonstrated for joining different material combinations (e.g., carbon fiber composite to 7075 Al alloy, 7075 Al alloy to 7075 Al alloy, and 7075 Al alloy to casting Al Aural 5) with a unified technique. Crack-free joint with adequate mechanical interlocking resulted in good mechanical joint strength for each material combination. Then, the process was successfully scaled up by producing multiple joints without any cracks on larger CFC-Al and Al-Al components by the new integrated system, bringing it closer to industrial application.

Lim, Yong Chae [ORNL] (ORCID:0000000321773988)↗