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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

Flow Patterns During Friction Stir Welding

Friction Stir Welding is a relatively new technique for welding that uses a cylindrical pin or nib inserted along the weld seam. The nib (usually threaded) and the shoulder in which it is mounted are rapidly rotated and advanced along the seam. Extreme deformation takes place leaving a fine equiaxed structure in the weld region., The flow of metal during Friction Stir Welding is investigated using a faying surface tracer and a nib frozen in place during welding. It is shown that material is transported by two processes. The first is a wiping of material from the advancing front side of the nib onto a zone of material that rotates and advances with the nib. The material undergoes a helical motion within the rotational zone that both rotates and advances and descends in the wash of the threads on the nib and rises on the outer part of the rotational zone. After one or more rotations, this material is sloughed off in its wake of the nib, primarily on the advancing side. The second process is an entrainment of material from the front retreating side of the nib that fills in between the sloughed off pieces from the advancing side.

Guerra, M.↗
NASA NTRS2012

Manufacturing of 5.5 Meter Diameter Cryogenic Fuel Tank Domes for the NASA Ares I Rocket

The Ares I rocket is the first launch vehicle scheduled for manufacture under the National Aeronautic and Space Administration s (NASA s) Constellation program. A series of full-scale Ares I development articles have been constructed on the Robotic Weld Tool at the NASA George C. Marshall Space Flight Center in Huntsville, Alabama. The Robotic Weld Tool is a 100 ton, 7-axis, robotic manufacturing system capable of machining and friction stir welding large-scale space hardware. This presentation will focus on the friction stir welding of 5.5m diameter cryogenic fuel tank components; specifically, the liquid hydrogen forward dome (LH2 MDA) and the common bulkhead manufacturing development articles (CBMDA). The LH2 MDA was the first full-scale, flight-like Ares I hardware produced under the Constellation Program. It is a 5.5m diameter elliptical dome assembly consisting of eight gore panels, a y-ring stiffener and a manhole fitting. All components are made from aluminum-lithium alloy 2195. Conventional and self-reacting friction stir welding was used on this article. Manufacturing solutions will be discussed including the implementation of photogrammetry, an advanced metrology technique, as well as fixtureless welding. The LH2 MDA is the first known fully friction stir welded dome ever produced. The completion of four Common Bulkhead Manufacturing Development Articles (CBMDA) will also be highlighted. Each CBMDA consists of a 5.5m diameter spun-formed dome friction stir welded to a y-ring stiffener. The domes and y-rings are made of aluminum 2014 and 2219 respectively. An overview of CBMDA manufacturing processes and the effect of tooling on weld defect formation will be discussed.

Jones, Ronald E.↗
NASA NTRS2016

Origins of Line Defects in Self-Reacting Friction Stir Welds and Their Impact on Weld Quality

Friction stir welding (FSWing) is a solid state joining technique which reduces the occurrence of typical defects formed in fusion welds, especially of highly alloyed metals. Although the process is robust for aluminum alloys, occasional reductions in the strength of FSWs have been observed. Shortly after the NASA-MSFC implemented a variation of FSW called self-reacting (SR), low strength properties were observed. At that time, this reduction in strength was attributed to a line defect. At that time, the limited data suggested that the line defect was related to the accumulation of native oxides that form on the weld lands and faying surfaces. Through a series of improved cleaning methods, tool redesign, and process parameter modifications, the reduction in the strength of the SR-FSWs was eliminated. As more data has been collected, the occasional reduction in the strength of SR-FSW still occurs. These occasional reductions indicate a need to reexamine the underlying causes. This study builds off a series of self reacting (SR)-FSWs that were made in 3 different thickness panels of AA2219 (0.95, 1.27 and 1.56 cm) at 2 different weld pitches. A bead on plate SR-FSW was also made in the 1.56 cm thick panel to understand the contribution of the former faying surfaces. Copper tracer studies were used to understand the flow lines associated with the weld tool used. The quality of the SR-FSWs was evaluated from tensile testing at room temperature. Reductions in the tensile strength were observed in some weldments, primarily at higher weld pitch or tool rotations. This study explores possible correlations between line defects and the reduction of strength in SR-FSWs. Results from this study will assist in a better understand of the mechanisms responsible for reduced tensile strength and provide methodology for minimizing their occurrence.

Schneider, Judy↗
NASA NTRS2013

Vision Systems Illuminate Industrial Processes

When NASA designs a spacecraft to undertake a new mission, innovation does not stop after the design phase. In many cases, these spacecraft are firsts of their kind, requiring not only remarkable imagination and expertise in their conception but new technologies and methods for their manufacture. In the realm of manufacturing, NASA has from necessity worked on the cutting-edge, seeking new techniques and materials for creating unprecedented structures, as well as capabilities for reducing the cost and increasing the efficiency of existing manufacturing technologies. From friction stir welding enhancements (Spinoff 2009) to thermoset composites (Spinoff 2011), NASA s innovations in manufacturing have often transferred to the public in ways that enable the expansion of the Nation s industrial productivity. NASA has long pursued ways of improving upon and ensuring quality results from manufacturing processes ranging from arc welding to thermal coating applications. But many of these processes generate blinding light (hence the need for special eyewear during welding) that obscures the process while it is happening, making it difficult to monitor and evaluate. In the 1980s, NASA partnered with a company to develop technology to address this issue. Today, that collaboration has spawned multiple commercial products that not only support effective manufacturing for private industry but also may support NASA in the use of an exciting, rapidly growing field of manufacturing ideal for long-duration space missions.

Source record↗
NASA NTRSDate not supplied

High Energy Hydroforming Friction Stir Welded 2050 Al-Li Blanks for Aerospace Domes and Cones

Friction stir welded (FSW) aluminum blanks offer larger preform sizes than available from the mill in single width plates. Large blanks made from aerospace-grade aluminum alloys are essential for making large domes and cones for launch vehicles and crew vehicles. Previous research efforts have demonstrated >5m FSW blanks can be formed into large domes or cones using spin forming, but the subsequent solution heat treatment consistently led to abnormal grain growth (AGG). The AGG phenomenon occurs because the FSW blanks must be spin formed in the -O annealed temper to withstand the high strain process without cracking. Subsequently, the solution heat treatment process leads to the onset of AGG, whereby a small number of grains grow much larger than the surrounding matrix. Ultimately, the large grains and bimodal grain-size distribution leads to unacceptable ductility in the short-transverse direction of the part. Alternatively, explosive hydroforming is a nascent process that can be applied to large and thick aerospace-grade aluminum alloy blanks in the -T3 temper and only require a post-forming artificial aging process to a -T8. Avoiding the solution heat treatment (SHT) process mitigates AGG, and also eliminates the need for very rare drop-furnace quench baths that can accommodate a part size larger than 5m in diameter. This presentation summarizes a Lockheed Martin-led effort that demonstrated explosive hydroforming of a 1.9m diameter, 39mm thick 2050 aluminum lithium FSW blank. Details will be provided on the process flow, mechanical properties, and metallographic analyses. This work was performed in partnership with NASA Langley Research Center (LaRC) under a NASA Announcement of Collaboration Opportunities program.

Friction stir welded blank↗
NASA NTRSDate not supplied

Refill Friction Stir Spot Welding as an Alternative Joining Method for Wing Spar Structures

Since the introduction of refill friction stir spot welding (RFSSW) in the early 2000s, numerous evaluations of properties, performance, and prototypes have been documented. RFSSW is a solid-state spot joining technique that is being evaluated as a rivet replacement technology for aerospace structures and fuselage fabrication. A production evaluation of overlapping wing skin assembly was completed and experimentation on stringer-stiffened curvilinear panels is underway. Weld properties were evaluated for spots produced on bare sheet as well as for sections with sealant applied. Furthermore, evaluations of the performance of repaired spots using the RFSSW process is demonstrated. Characterization of the weld interface, heat-affected zone, and complete through-thickness consolidation via computed tomography is presented.

Solid-state joining↗
NASA NTRS2000

Demonstration of a Large-Scale Tank Assembly Via Circumferential Friction Stir Welds

Five (5) each 14-foot diameter circumferential FSWelds were conducted on the modified CWT, two (2) each pathfinder and three (3) each assembly welds Tapered circumferential welds were successfully demonstrated The use of a closeout anvil was successfully demonstrated during one of the pathfinder welds Considerable difficulty maintaining joint f it-up during the weld process Anvil deflections Hardware dimensional tolerances Inadequate clamping Variations in the heat sink characteristics of the circumferential anvil as compared to the test panel anvil

Jones, Chip↗
NASA NTRS2008

Effect of Weld Tool Geometry on Friction Stir Welded AA2219-T87 Properties

In this study, flat panels of AA2219-T87 were friction stir welded (FSWed) using weld tools with tapered pins The three pin geometries of the weld tools included: 0 (straight cylinder), 30 , and 60 angles on the frustum. For each weld tool geometry, the FSW process parameters were optimized to eliminate defects. A constant heat input was maintained while varying the process parameters of spindle rpm and travel speed. This provided a constant heat input for each FSW weld panel while altering the hot working conditions imparted to the workpiece. The resulting mechanical properties were evaluated from tensile test results of the FSW joint.

Querin, Joseph A.↗
NASA NTRS2013

Net Shape Spin Formed Cryogenic Aluminum Lithium Cryogenic Tank Domes for Lower Cost Higher Performance Launch Vehicles

With the goal of lower cost (simplified manufacturing and lower part count) and higher performance (higher strength to weight alloys) the NASA Technical Maturation Program in 2006 funded a proposal to investigate spin forming of space launch vehicle cryogenic tank domes. The project funding continued under the NASA Exploration Technology Development Program through completion in FY12. The first phase of the project involved spin forming of eight, 1 meter diameter "path finder" domes. Half of these were processed using a concave spin form process (MT Aerospace, Augsburg Germany) and the other half using a convex process (Spincraft, Boston MA). The convex process has been used to produce the Ares Common Bulkhead and the concave process has been used to produce dome caps for the Space Shuttle light weight external tank and domes for the NASDA H2. Aluminum Lithium material was chosen because of its higher strength to weight ratio than the Aluminum 2219 baseline. Aluminum lithium, in order to obtain the desired temper (T8), requires a cold stretch after the solution heat treatment and quench. This requirement favors the concave spin form process which was selected for scale up. This paper describes the results of processing four, 5.5 meter diameter (upper stage scale) net shaped spin formed Aluminum Lithium domes. In order to allow scalability beyond the limits of foundry and rolling mills (about 12 foot width) the circular blank contained one friction stir weld (heavy lifter scales require a flat blank containing two welds). Mechanical properties data (tensile, fracture toughness, stress corrosion, and simulated service testing) for the parent metal and weld will also be discussed.

Curreri, Peter A.↗
NASA NTRS2008

Phased Array Ultrasound: Initial Development of PAUT Inspection of Self-Reacting Friction Stir Welds

This slide presentation reviews the development of Phased Array Ultrasound (PAUT) as a non-destructive examination method for Self Reacting Friction Stir Welds (SR-FSW). PAUT is the only NDE method which has been shown to detect detrimental levels of Residual Oxide Defect (ROD), which can result in significant decrease in weld strength. The presentation reviews the PAUT process, and shows the results in comparison with x-ray radiography.

Rairigh, Ryan↗
NASA NTRS2003

Friction Stir Welding of Tapered Thickness Welds Using an Adjustable Pin Tool

Friction stir welding (FSW) can be used for joining weld lands that vary in thickness along the length of the weld. An adjustable pin tool mechanism can be used to accomplish this in a single-pass, full-penetration weld by providing for precise changes in the pin length relative to the shoulder face during the weld process. The difficulty with this approach is in accurately adjusting the pin length to provide a consistent penetration ligament throughout the weld. The weld technique, control system, and instrumentation must account for mechanical and thermal compliances of the tooling system to conduct tapered welds successfully. In this study, a combination of static and in-situ measurements, as well as active control, is used to locate the pin accurately and maintain the desired penetration ligament. Frictional forces at the pin/shoulder interface were a source of error that affected accurate pin position. A traditional FSW pin tool design that requires a lead angle was used to join butt weld configurations that included both constant thickness and tapered sections. The pitch axis of the tooling was fixed throughout the weld; therefore, the effective lead angle in the tapered sections was restricted to within the tolerances allowed by the pin tool design. The sensitivity of the FSW process to factors such as thickness offset, joint gap, centerline offset, and taper transition offset were also studied. The joint gap and the thickness offset demonstrated the most adverse affects on the weld quality. Two separate tooling configurations were used to conduct tapered thickness welds successfully. The weld configurations included sections in which the thickness decreased along the weld, as well as sections in which the thickness increased along the weld. The data presented here include weld metallography, strength data, and process load data.

Adams, Glynn↗
NASA NTRS2000

Lack of Penetration in Friction Stir Welds: Effects on Mechanical Properties and NDE Feasibility

This presentation reviews the issue of lack of penetration (LOP) in Friction Stir Welding and the feasibility of using non-destructive tests to detect . Friction Stir Welding takes place in the solid phase below the melting point of the materials to be joined. It thus gives the ability to join materials which are difficult to fusion weld, for example 2000 and 7000 aluminium alloys. This process though can result in a lack of penetration, due to an incomplete penetration of the DXZ. This is frequently referred to as a "kissing bond", which requires micro examination to detect. The presentation then discusses the surface crack tension tests. It then reviews the simulated service test and results. It then discusses the feasibility of using non-destructive examination to detect LOP, the forms of test which can be used, and the results the tests.

Kinchen, David G.↗
NASA NTRS2004

Computer Tomography 3-D Imaging of the Metal Deformation Flow Path in Friction Stir Welding

In friction stir welding, a rotating threaded pin tool is inserted into a weld seam and literally stirs the edges of the seam together. This solid-state technique has been successfully used in the joining of materials that are difficult to fusion weld such as aluminum alloys. To determine optimal processing parameters for producing a defect free weld, a better understanding of the resulting metal deformation flow path is required. Marker studies are the principal method of studying the metal deformation flow path around the FSW pin tool. In our study, we have used computed tomography (CT) scans to reveal the flow pattern of a lead wire embedded in a FSW weld seam. At the welding temperature of aluminum, the lead becomes molten and thus tracks the aluminum deformation flow paths in a unique 3-dimensional manner. CT scanning is a convenient and comprehensive way of collecting and displaying tracer data. It marks an advance over previous more tedious and ambiguous radiographic/metallographic data collection methods.

Schneider, Judy↗
NASA NTRS2009

Pin Tool Geometry Effects in Friction Stir Welding

In friction stir welding (FSW) there is significant evidence that material can take one of two different flow paths when being displaced from its original position in front of the pin tool to its final position in the wake of the weld. The geometry of the pin tool, along with the process parameters, plays an important role in dictating the path that the material takes. Each flow path will impart a different thermomechanical history on the material, consequently altering the material microstructure and subsequent weld properties. The intention of this research is to isolate the effect that different pin tool attributes have on the flow paths imparted on the FSWed material. Based on published weld tool geometries, a variety of weld tools were fabricated and used to join AA2219. Results from the tensile properties and microstructural characterization will be presented.

Querin, J. A.↗
NASA NTRS2002

Compression Buckling Behavior of Large-Scale Friction Stir Welded and Riveted 2090-T83 Al-Li Alloy Skin-Stiffener Panels

To evaluate the potential of friction stir welding (FSW) as a replacement for traditional rivet fastening for launch vehicle dry bay construction, a large-scale friction stir welded 2090-T83 aluminum-lithium (Al-Li) alloy skin-stiffener panel was designed and fabricated by Lockheed-Martin Space Systems Company - Michoud Operations (LMSS) as part of NASA Space Act Agreement (SAA) 446. The friction stir welded panel and a conventional riveted panel were tested to failure in compression at the NASA Langley Research Center (LaRC). The present paper describes the compression test results, stress analysis, and associated failure behavior of these panels. The test results provide useful data to support future optimization of FSW processes and structural design configurations for launch vehicle dry bay structures.

Hoffman, Eric K.↗
NASA NTRS2015

Performance Improvement of Friction Stir Welds by Better Surface Finish

The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled.

Russell, Sam↗
NASA NTRS1998

Low-Temperature Friction-Stir Welding of 2024 Aluminum

Solid state friction-stir welding (FSW) has been demonstrated to involve dynamic recrystallization producing ultra-fine, equiaxed grain structures to facilitate superplastic deformation as the welding or joining mechanism. However, the average residual, equiaxed, grain size in the weld zone has ranged from roughly 0.5 micron to slightly more than 10 micron, and the larger weld zone grain sizes have been characterized as residual or static grain growth as a consequence of the temperatures in the weld zone (where center-line temperatures in the FSW of 6061 Al have been shown to be as high as 480C or -0.8 T(sub M) where T(sub M) is the absolute melting temperature)). In addition, the average residual weld zone grain size has been observed to increase near the top of the weld, and to decrease with distance on either side of the weld-zone centerline, an d this corresponds roughly to temperature variations within the weld zone. The residual grain size also generally decreases with decreasing FSW tool rotation speed. These observations are consistent with the general rules for recrystallization where the recrystallized grain size decreases with increasing strain (or deformation) at constant strain rate, or with increasing strain-rate, or with increasing strain rate at constant strain; especially at lower ambient temperatures, (or annealing temperatures). Since the recrystallization temperature also decreases with increasing strain rate, the FSW process is somewhat complicated because the ambient temperature, the frictional heating fraction, and the adiabatic heating fraction )proportional to the product of strain and strain-rate) will all influence both the recrystallization and growth within the FSW zone. Significantly reducing the ambient temperature of the base metal or work pieces to be welded would be expected to reduce the residual weld-zone grain size. The practical consequences of this temperature reduction would be the achievement of low temperature welding. This study compares the residual grain sizes and microstructures in 2024 Al friction-stir welded at room temperature (about 30C and low temperature (-30C).

Benavides, S.↗
NASA NTRS1999

Fundamental Study of Material Flow in Friction Stir Welds

The presented research project consists of two major parts. First, the material flow in solid-state, friction stir, butt-welds as been investigated using a marker insert technique. Changes in material flow due to welding parameter as well as tool geometry variations have been examined for different materials. The method provides a semi-quantitative, three-dimensional view of the material transport in the welded zone. Second, a FSW process model has been developed. The fully coupled model is based on fluid mechanics; the solid-state material transport during welding is treated as a laminar, viscous flow of a non-Newtonian fluid past a rotating circular cylinder. The heat necessary for the material softening is generated by deformation of the material. As a first step, a two-dimensional model, which contains only the pin of the FSW tool, has been created to test the suitability of the modeling approach and to perform parametric studies of the boundary conditions. The material flow visualization experiments agree very well with the predicted flow field. Accordingly, material within the pin diameter is transported only in the rotation direction around the pin. Due to the simplifying assumptions inherent in the 2-D model, other experimental data such as forces on the pin, torque, and weld energy cannot be directly used for validation. However, the 2-D model predicts the same trends as shown in the experiments. The model also predicts a deviation from the "normal" material flow at certain combinations of welding parameters, suggesting a possible mechanism for the occurrence of some typical FSW defects. The next step has been the development of a three-dimensional process model. The simplified FSW tool has been designed as a flat shoulder rotating on the top of the workpiece and a rotating, cylindrical pin, which extends throughout the total height of the flow domain. The thermal boundary conditions at the tool and at the contact area to the backing plate have been varied to fit experimental data such as temperature profiles, torque and tool forces. General aspects of the experimentally visualized material flow pattern are confirmed by the 3-D model.

Reynolds, Anthony P.↗