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NASA NTRS2012

The Evolution of Friction Stir Welding Theory at Marshall Space Flight Center

From 1995 to the present the friction stir welding (FSW) process has been under study at Marshall Space Flight Center (MSFC). This is an account of the progressive emergence of a set of conceptual tools beginning with the discovery of the shear surface, wiping metal transfer, and the invention of a kinematic model and making possible a treatment of both metallurgical structure formation and process dynamics in friction stir welding from a unified point of view. It is generally observed that the bulk of the deformation of weld metal around the FSW pin takes place in a very narrow, almost discontinuous zone with high deformation rates characteristic of metal cutting. By 1999 it was realized that this zone could be treated as a shear surface like that in simple metal cutting models. At the shear surface the seam is drawn out and compressed and pressure and flow conditions determine whether or not a sound weld is produced. The discovery of the shear surface was followed by the synthesis of a simple 3- flow kinematic model of the FSW process. Relative to the tool the flow components are: (1) an approaching translational flow at weld speed V, (2) a rotating cylindrical plug flow with the angular velocity of the tool , and (3) a relatively slow ring vortex flow (like a smoke ring) encircling the tool and driven by shoulder scrolls and pin threads. The rotating plug flow picks up an element of weld metal, rotates it around with the tool, and deposits it behind the tool ( wiping metal transfer ); it forms plan section loops in tracers cut through by the tool. Radially inward flow from the ring vortex component retains metal longer in the rotating plug and outward flow expels metal earlier; this interaction forms the looping weld seam trace and the tongue and groove bimetallic weld contour. The radial components of the translational and ring vortex flows introduce parent metal intrusions into the small grained nugget material close to the tool shoulder; if this feature is pronounced, nugget collapse may result. Certain weld features, in particular internal banding seen in transverse section as onion rings and associated surface ridges called tool marks , have long implied an oscillation flow component, but have only recently been attributed in the literature to tool eccentricity. Rotating plug shape, typically a hollow cylinder flared at the end where it sticks to the shoulder, varies as pressure distribution on the tool determines where sticking occurs. Simplified power input estimates balanced against heat loss estimates give reasonable temperature estimates, explain why the power requirement changes hardly at all over a wide range of RPM s, and yield isotherms that seem to fall along boundaries of parameter windows of operation.

Nunes, Arthur C.↗

NASA NTRS2000

Bubble Formation on a Wall in Cross-Flowing Liquid and Surrounding Fluid Motion,With and Without Heating

Application of gas-liquid two-phase flow systems for space-based thermal management and for the HEDS program demands a precise control of bubble size distribution in liquid. The necessity of bulk liquid motion for controlling bubble size and frequency in the space environment has been suggested by recent studies on pool, forced convection boiling and bubble formation in flowing liquid. The present work, consisting of two parts, explores bubble generation at wall in a cross-flowing liquid, i.e., in a forced convection boiling configuration. A schematic is shown. The first part looks into the bubble formation process under isothermal conditions in a reduced gravity environment, by injecting gas through a hole in the wall of a flowing liquid channel. In the latter part with channel wall heating, flow and temperature fields near a single bubble are studied under normal (1-g) and micro-gravity (mu-g) conditions. The objective of the isothermal experiments is to experimentally investigate the effects of liquid cross-flow velocity, gas flow rate, and orifice diameter on bubble formation. Data were taken mainly under reduced gravity conditions but some data were taken in normal gravity for comparison. The reduced gravity experiment was conducted aboard the NASA DC-9 Reduced Gravity Aircraft. The results show that the process of bubble formation and detachment depends on gravity, the orifice diameter (D(sub N)), the gas flow rate (Q(sub g)), and the liquid cross-flow velocity (U(sub L)). The reduced gravity data are shown. The data are analyzed based on a force balance, and two different detachment mechanisms are identified. When the gas momentum is large, the bubble detaches from the injection orifice as the gas momentum overcomes the attaching effects of liquid drag and inertia. The surface tension force is much reduced because a large part of the bubble pinning edge at the orifice is lost as the bubble axis is tilted by the liquid flow. When the gas momentum is small, the force balance in the liquid flow direction is important, and the bubble detaches when the bubble axis inclination exceeds a certain angle. With wall heating, liquid motion around an air bubble in cross-flowing 2cs silicone oil is experimentally investigated in 1-g. A spectral element based steady 2D numerical model is also developed. The traces of particles from experimental flow visualization and the corresponding computed streamlines are shown. At the upstream side of the bubble facing the cross-flow, thermocapillary and forced convection create liquid motion away from the wall, up along the surface. At the downstream side, a competing interaction between the two creates a recirculation cell, causing the bulk liquid to stagnate on the surface and separate thereafter. The important dimensionless parameters are - Surface tension and local cross-flow Reynolds numbers R(sub sigma)(U(sub ref)a/v) and Re(sub loc)(U(sub L)a/v), respectively based on reference thermocapillary U(sub ref)(sigma(sub T)Delta.T/mu, Delta T=T(sub wall)-T(sub liquid)) and local cross-flow velocity U(sub L), Prandtl number P(sub r) and Grashoff number Gr(rho.g.beta.DeltaTa(sup 3)/mu.v). Variation of the stagnation point with R(sub sigma) and Re(sub loc) is shown. Also shown are good agreement between experimental and numerical results in 1-g. The computational model is extended to mu-g condition to investigate temperature and velocity on the bubble surface, stagnation and reattachment points of the recirculation cell and wall heat transfer. It is observed that wall heating significantly alters the flow field around the bubble and thus the forces acting on the bubble, which control its detachment. Thus a combination of heating and liquid cross-flow can be utilized to precisely control bubble formation in a mu-g environment.

Bhunia, Avijit↗

NASA NTRS2005

Influence of Nucleation Mechanisms on the Radiative Properties of Deep Convective Clouds and Subvisible Cirrus in CRYSTAL/FACE

During the past few years we have conducted work on several different topics, as reflected by our publications. As one of the Co-Project scientists for The Cirrus Regional Study of Tropical Anvils and Cirrus Layers - Florida Area Cirrus Experiment (CRYSTAL FACE) we worked to help design the mission and then conduct it in the field. Another major activity during the past two years has been to pull together various groups to formulate plans for follow on missions to CRYSTAL FACE. We organized a workshop at the University of Colorado during the summer of 2003 to assess the best locations for future missions. Working with a group of about 10 scientists from around the country we prepared a science-planning document (Tropical Composition, Cloud and Climate Coupling Experiment (TC(sup 4)) that outlined the rationale, locations, strategy to accomplish the goals, and possible payloads for a set of three tropical missions. We also prepared background materials for various NRAs being prepared at NASA Headquarters for missions in Costa Rica, Darwin and Guam. In conjunction with the group at NASA Ames we have helped build a new numerical model for deep convection and have applied that model to simulate the CRYSTAL data. Our goal in particular has been to better understand how convection distributes water vapor isotopes. CRYSTAL observations of water isotopes are very different from those suggested by previous workers who assumed the isotopes would obey Rayleigh fractionation. The water isotope study has several implications. First it is a check on the realism of the deep convection model. Second, the isotopes are a measure of the precipitation removal in the atmosphere. Hence they provide a constraint on a parameter that is difficult to otherwise measure. Finally it has been suggested that isotopes may be the key to unraveling the water transport into the stratosphere and upper troposphere. Such transport is critical both for the radiation balance and for stratospheric chemistry. Ours is the first model that is able to treat this transport. Our initial results have just been submitted to Geophys. Res. Lett (Smith et al., 2005). Essentially we are able to explain the vertical profiles of isotopes in the tropical tropopause transition layer. We are also able to account for stratospheric humidity and isotope abundances with this model. We have also been heavily involved in trying to improve our understanding of nitric acid condensation on ice. Gao et al (2004) have shown that water supersaturations above ice occur when the atmosphere is supersaturated with respect to nitric acid trihydrate. As one of the co-authors of that work, we suggested the mechanism that may explain why this is occurring. Essentially, ice does not like to grow near unit supersaturation, but does so because the water molecules can find sites on the ice surface to attach themselves to before they fly off the ice surface. This phenomena was well known in the 1960s when it was a source of debate about whether condensation and evaporation coefficients for ice would be the same. Evaporation does not require any molecular orientation, while condensation does, so it was possible that the coefficients would differ. They don't differ because the water molecules rapidly move across the surface and find places to attach. Nitric acid may be occupying these preferred sites and therefore the water molecules can't find a desirable place to attach. We anticipate that this research will be the subject of laboratory work during the coming few years. Another possibility that has been suggested is that cubic ice is forming in clouds. We have measured the vapor pressure of cubic ice, and plan to publish that result in the next few months. We have also been working on additional aspects of the condensation of nitric acid on ice. With Y. Kondo we studied the condensation of NOy on ice using the SOLVE data. Gamblin et al. have continued this work. The CRYSTAL NOy and HNO, groups have shown th their data can be fit using standard Langmuir isotherms as suggested in some, but not all, laboratory studies. We have found in the SOLVE data set that this is not the case. Moreover some laboratory studies show there are important kinetic effects that may be occurring in the atmosphere limiting the transfer of nitric acid to the ice. The SOLVE data seem consistent with these studies. We are currently re-analyzing the CRYSTAL data to look for these kinetic effects. There are a number of implications of these studies. One of the more interesting is that the nitric acid coating on ice can be used as a cloud clock to determine how long the cloud parcel has been in existence. We have also been involved with several laboratory studies. We have worked to improve the database on ice optical constants, which are critical for remote sensing. We have also studied the ways in which ice nucleates on clays. We suspect now that the standard theories used for depositional ice nucleation are completely incorrect. Further work will be needed to develop a new theory.

Toon, Owen B.↗

NASA NTRS1994

Photoevaporation of disks around massive stars and application to ultracompact H II regions

Young massive stars produce sufficient Lyman continuum photon luminosity Phi(sub i) to significantly affect the structure and evolution of the accretion disks surrounding them. A nearly static, ionized, isothermal 10(exp 4) K atmosphere forms above the neutral disk for disk radii r less than r(sub g) = 10(exp 15) M(sub 1) cm, where M(sub *) = 10 solar mass M(sub 1) is the stellar mass. For r approximately greater than r(sub g) the diffuse field created by hydrogen recombinations to the ground state in the photoionized gas above the disk produces a steady evaporation at the surface of the disk, and this H II gas flows freely out to the ISM (the 'disk wind'). The detailed structure depends on the mass-loss rate dot-M(sub w) of the fast, approximately greater than 1000 km/sec, stellar wind from the massive star. A critical mass-loss rate dot-M(sub cr) is defined such that the ram pressure of the stellar wind equals the thermal pressure of the H II atmosphere at r(sub g). In the weak stellar wind solution, dot-M(sub w) less than dot-M(sub cr), the diffuse photons from the atmosphere above r(sub g) produce a photoevaporative mass-loss rate from the disk at r approximately greater than r(sub g) of order 1 x 10(exp -5)(Phi(sub 49))(exp 1/2)(M(sub 1))(exp 1/2) solar mass/year, where Phi(sub i) = 10(exp 49) Phi(sub 49)/sec. The resulting slow (10 to 50 km/sec) ionized outflow, which persists for approximately greater than 10(exp 5) year for disk masses M(sub d) approximately 0.3 M(sub *), may explain the observational characteri stics of unresolved, ultracompact H II regions. In the strong stellar wind solution, dot-M(sub w) greater than dot-M(sub cr), the ram pressure of the stellar wind blows down the atmosphere for r less than r(sub g) and allows the stellar photons to penetrate to greater radii and smaller heights. A slow, ionized outflow produced mainly by diffuse photons is again created for r less than r(sub g); however, it is now dominated by the flow at r(sub w)(greater than r(sub g)), the radius at which the stellar wind ram pressure equals the thermal pressure in the evaporating flow. The mass-loss rate from the disk is of order 6 x 10(exp -5)dot-M(sub w-6) v(sub w8)(Phi (sub 49))(exp -1/2) solar mass/year, where dot-M(sub w-6) = M(sub w)/10(exp -6) solar mass/year and v(sub w8) = v(sub w)/1000 km/sec is the stellar wind velocity. The resulting outflow, which also persists for approximately greater than 10(exp 5) year may explain many of the more extended (r approximately greater than 10(exp 16) cm) ultracompact H II regions. Both the weak-wind and the strong-wind models depend entirely on stellar parameters Phi(sub i), M(sub *), dot-M(sub w)) and are independent of disk parameters as long as an extended r much greater than (r(sub g)), neutral disk exists. We compare both weak-wind and strong-wind model results to the observed radio free-free spectra and luminosities of ultracompact H II regions and to the interesting source MWC 349.

Hollenbach, David↗