Internal Friction Reduction Tool (For Self-Reacting Friction Stir Welding)
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The analytical developments and experimental investigations performed in assessing the effect of internal friction on rotor systems dynamic performance are documented. Analytical component models for axial splines, Curvic splines, and interference fit joints commonly found in modern high speed turbomachinery were developed. Rotor systems operating above a bending critical speed were shown to exhibit unstable subsynchronous vibrations at the first natural frequency. The effect of speed, bearing stiffness, joint stiffness, external damping, torque, and coefficient of friction, was evaluated. Testing included material coefficient of friction evaluations, component joint quantity and form of damping determinations, and rotordynamic stability assessments. Under conditions similar to those in the SSME turbopumps, material interfaces experienced a coefficient of friction of approx. 0.2 for lubricated and 0.8 for unlubricated conditions. The damping observed in the component joints displayed nearly linear behavior with increasing amplitude. Thus, the measured damping, as a function of amplitude, is not represented by either linear or Coulomb friction damper models. Rotordynamic testing of an axial spline joint under 5000 in.-lb of static torque, demonstrated the presence of an extremely severe instability when the rotor was operated above its first flexible natural frequency. The presence of this instability was predicted by nonlinear rotordynamic time-transient analysis using the nonlinear component model developed under this program. Corresponding rotordynamic testing of a shaft with an interference fit joint demonstrated the presence of subsynchronous vibrations at the first natural frequency. While subsynchronous vibrations were observed, they were bounded and significantly lower in amplitude than the synchronous vibrations.
Using echo pulse and resonance rod methods, internal friction in pure aluminum was studied as a function of frequency, hardening temperature, time (internal friction relaxation) and impurity content. These studies led to the conclusion that internal friction in these materials depends strongly on dislocation structure and on elastic interactions between structure defects. It was found experimentally that internal friction relaxation depends on the cooling rate and on the impurity content. Some parameters of the dislocation structure and of the diffusion process were determined. It is shown that the dislocated dependence of internal friction can be used as a method of nondestructive testing of the impurity content of high-purity materials.
An attempt has been made to invert a large set of attenuation data for Love waves and toroidal oscillations in the earth, using a recent method by Backus and Gilbert. The difficulty in finding an acceptable model of internal friction which explains the data, under the assumption that the internal friction is independent of frequency, casts doubt on the validity of this assumption. A frequency-dependent model of internal friction is presented which is in good agreement with the seismic data and with recent experimental measurements of attenuation in rocks.
Optical observations of rotating space debris near GEO contain important information on size, shape, composition, and rotational states, but these aspects are difficult to extract due to data limitations and the high number of degrees of freedom in the modeling process. For tri-axial rigid debris objects created by satellite fragmentations, the most likely initial rotation state has a large component of initial angular velocity directed along the intermediate axis of inertia, leading to large angular reorientations of the body on the timescale of the rotation period. This lends some support to the simplest possible interpretation of light curves -- that they represent sets of random orientations of the objects of study. However, effects of internal friction and solar radiation are likely to cause significant modification of rotation states within a time as short as a few orbital periods. In order to examine the rotational dynamics of debris objects under the influences of these effects, a set of seven first-order coupled equations of motion were assembled in state form: three are Euler equations describing the rates of change of the components of angular velocity in the body frame, and four describe the rates of change of the components of the unit quaternion. Quaternions are a four-dimensional extension of complex numbers that form a seamless, singularity-free representation of body orientation on S3. The Euler equations contain explicit terms describing torque from solar radiation in terms of spherical harmonics, and terms representing effects of a prescribed rate of internal friction. Numerical integrations of these equations of motion are being performed, and results will be presented. Initial tests show that internal friction without solar radiation torque leads to rotation about the maximum principal axis of inertia, as required, and solar radiation torque is expected to lead to spin-up of objects. Because the axis of maximum rotational inertia tends to be roughly coincident with the normal to the largest projected cross-sectional area, internal friction is expected to lead to reduced variation of light curve amplitudes at a given phase angle, but a large dependence of the same on phase angle. At a given phase angle, databases are generated which contain reflected intensities for comprehensive sets of equally-likely orientations, represented as unit quaternions. When projected onto three dimensions (S2) and color-coded by intensity, the set is depicted as points within a solid, semi-transparent unit sphere, within which all possible reflected intensities for an object at a given phase angle may be inspected simultaneously. Rotational sequences are represented by trajectories through the sphere. Databases are generated for each of a set of phase angles separately, forming a comprehensive dataset of reflected intensities spanning all object orientations and solar phase angles. Symmetries in the problem suggest that preferred rotation states are likely, defined relative to the object-sun direction in inertial space and relative to the maximum principal axis of inertia in the body coordinate system. Such rotation states may greatly simplify the problem of light curve interpretation by reducing the number of degrees of freedom in the problem.
Room temperature internal friction (Q sup-1) values of the 0.00002-0.00003 range were achieved with lunar rock 70215,85 by thorough outgassing procedures in ultrahigh vacuum. Results are presented on the temperature dependence of Q sup -1 as measured in the range 25 C to 600 C along with some data on the change in Q sup -1 with pressure in ultrahigh vacuum. The temperature dependence shows the existence of an internal friction peak at around 200 C followed at high temperatures by an extensive region with flat Q sup -1 (approximately 0.001); the work at ultrahigh vacuum shows decreases in the internal friction with decreases in ambient pressure even in the range 10 to the -8 to 10 to the -10 power torr.
The effect of rotor internal friction on the system's stability was studied when operated above the first critical speed. This internal friction is commonly caused by sliding press fits or sliding splines. Under conditions of high speed and low bearing damping, these systems will occassionally whirl at a frequency less than the shaft's rotational speed. This subsynchronous precession is a self excited phenomenon and stress reversals are created. This phenomenon was observed during engine testing. The reduction of spline friction and/or the inclusion of squeeze film damping have controlled the instability. Case history and the detail design of the squeeze film dampers is discussed.
Specially designed sensor is attached to or imbedded in propellant. When sensor is driven into vibration, it moves with a phase lag directly proportional to internal friction or loss coefficent. Resonance frequency of the system is related to Young's modulus. Modulus or internal friction can be monitored over long period of time.
Discovery of unlocked contacts in Deutsch Block terminal junctions in Solid Rocket Booster flight hardware prompted an investigation into pull test techniques to help insure against possible failures. Internal frictional forces between socket and pin and between wire and grommet were examined. Pull test force must be greater than internal friction yet less than the crimp strength of the pin or socket. For this reason, a 100 percent accurate test is impossible. Test tools were evaluated. Available tools are adequate for pull testing.
In order for Active Debris Removal to be accomplished, it is critically important to understand the probable rotation states of orbiting, spent rocket bodies. As compared to the question of characterizing small unresolved debris, in this problem there are several advantages: (1) objects are of known size, mass, shape and color, (2) they have typically been in orbit for a known period of time, (3) they are large enough that resolved images may be obtainable for verification of predicted orientation, and (4) the dynamical problem is simplified to first order by largely cylindrical symmetry. It is also nearly certain for realistic rocket bodies that internal friction is appreciable in the case where residual liquid or, to a lesser degree, unconsolidated solid fuels exist. Equations of motion have been developed for this problem in which internal friction as well as torques due to solar radiation, magnetic induction, and gravitational gradient are included. In the case of pure cylindrical symmetry, the results are compared to analytical predictions patterned after the standard approach for analysis of symmetrical tops. This is possible because solar radiation and gravitational torques may be treated as conservative. Agreement between results of both methods ensures their mutual validity. For monotone symmetric cylinders, solar radiation torque vanishes if the center of mass resides at the geometric center of the object. Results indicate that in the absence of solar radiation effects, rotation states tend toward an equilibrium configuration in which rotation is about the axis of maximum inertia, with the axis of minimum inertia directed toward the center of the earth. Solar radiation torque introduces a modification to this orientation. The equilibrium state is asymptotically approached within a characteristic timescale given by a simple ratio of relevant characterizing parameters for the body in question. Light curves are simulated for the expected asymptotic final rotation states of model objects, and these are compared to data derived from physical models of the same objects, tested in the Optical Measurements Center at JSC. Comparison to relevant light curves from actual orbiting rocket bodies are also performed, and diagnostic features of such curves are examined.
Cryogenic seal tests were performed and Rulon A was selected for the subject nutating positive displacement expander. A four-chamber expander was designed and fabricated. A nitrogen reliquefier flow system was also designed and constructed for testing the cold expander. Initial tests were unsatisfactory because of high internal friction attributed to nutating Rulon inlet and outlet valve plates. Replacement of the nutating valves with cam-actuated poppet valves improved performance. However, no net nitrogen reliquefaction was achieved due to high internal friction. Computer software was developed for accurate calculation of nitrogen reliquefaction from a system such as that proposed. These calculations indicated that practical reliquefaction rates of 15 to 19 percent could be obtained. Due to mechanical problems, the nutating expander did not demonstrate its feasibility nor that of the system. It was concluded that redesign and testing of a smaller nutating expander was required to prove concept feasibility.
We have done a complete flowability characterization of the lunar soil simulant, JSC-1a, following closely the ASTM-6773 standard for the Schulze ring shear test. The measurements, which involve pre-shearing the material before each yield point, show JSC-1a to be cohesionless, with an angle of internal friction near 40 deg. We also measured yield loci after consolidating the material in a vibration table which show it to have significant cohesion (approximately equal to 1 kPa) and an angle of internal friction of about 60 deg. Hopper designs based on each type of flowability test differ significantly. These differences highlight the need to discern the condition of the lunar soil in the specific process where flowability is an issue. We close with a list not necessarily comprehensive of engineering rules of thumb that apply to powder flow in hoppers.
The mechanical stability of an impact crater is analyzed in this paper via a quasi-static, axisymmetric slip line theory of plasticity. The yield model incorporated is Mohr-Coulomb and a simplified rectangular profile is used for the transient cavity. The degree of stability (or instability) is described as a function of internal friction angle, depth/diameter ratio, and a dimensionless parameter. To match the observed slumping of large lunar craters the cohesion strength of the lunar surface material must be low (less than 20 bars) and the angle of internal friction must be less than 2 deg. It is not implausible that these failure strength characteristics are realized by freshly shocked rock.
The investigation reported shows that the internal friction of compressed LiF crystals which have been irradiated by gamma-rays at liquid nitrogen temperature recovers during isochronal annealing at a low linear rate. An analysis of the annealing process is conducted. It is concluded that the recovery of the internal friction is related to the interaction between dislocations and H centers. The H centers are produced by the gamma-rays.
The polycrystalline intermetallic alloys FeAl (50.9 to 58.2 percent Fe), NiAl (49.2 to 55.9 percent Ni) and CoAl (48.5 to 52.3 percent Co) have the B2 structure and are of interest for high temperature applications. The PUCOT (piezoelectric ultrasonic composite oscillator technique) has been used to measure mechanical damping or internal friction and Young's modulus has been used as a function of temperature and composition for these materials. The modulus data for six CoAl alloys at temperatures up to 1300 K are presented. Examples are given of the strain amplitude dependence of internal friction for four CoAl alloys. The curves showed the break away phenomenon and are interpreted in terms of a theory dealing with the pinning of dislocation lines and their eventual break away at large strain amplitudes. The dislocation density was calculated to be about 10 to the 8th per sq m. For all the compositions (X1) of CoAl studied, a single equation could be fitted to the data.
Previous studies have shown that very small amounts of absorbed volatiles only removed by outgassing in high vacuum and elevated temperatures-drastically increase the internal friction in terrestrial analogs of lunar basalt. Recently room temperature Q values as high as 2000 were achieved by thorough outgassing procedures in 10 to the 8th power torr. Results are presented on Q measurements for lunar rock 70215.85, along with some data on the effect on Q of a variety of gases. Data show that substantially greater increases in Q are obtainable in a lunar rock sample than in the terrestrial analog samples studied, and that in addition to H2O other gases also can make non-negligible contributions to the internal friction.
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Dislocation relaxation of silver and copper and asymmetry of Bordoni internal friction peak of metals