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At least 19 records

Literature Review on the Theory and Measurement of Dry Sliding Friction of Metals

Understanding the friction behavior between two sliding bodies can inform the design of machines, processing of materials, and simulation of dynamic processes. Kinetic friction is a complex phenomenon that depends on a multitude of factors such as sliding velocity, normal force, contact area, surface roughness, material properties, lubrication conditions, and thermal effects. This literature review covers the major known effects of sliding velocity, normal load, and surface roughness on the measured kinetic friction coefficient in the context of microscopic friction phenomena. Classic macroscale friction models are reviewed to illustrate approaches for simulating friction behavior. Prominent experimental friction setups within the literature are discussed with respect to achievable velocity and pressure regimes. The background information gathered here will be used to inform experimental procedures and modeling strategies of the exploratory research (ER) project titled “Measurement of Dynamic Friction via Kolsky Bar” (20200418ER).

36 MATERIALS SCIENCE↗

Frictional Contacts Between Individual Woody Biomass Particles under Wet and Dry Conditions

Friction between wood particles can be a critical property when designing processing equipment for creating cellulosic biofuels and similar natural products. Also, as wood processing is likely to occur year-round, understanding the friction between wet as well as dry wood particles can help design and model equipment, such as screw feeders. Here, a tribo-rheometry method was developed using a commercial rheometer that measured the torque required to rotate two contacting millimeter-scale wood chip particles. First, a range of normal forces were used to find the limits of the experimental method. Torque values were measured for seven pairs of wood chip particles at 1 N normal force under both dry and wet conditions, at both ambient conditions and in a humidity-controlled chamber. The torque required to rotate the wet particles was consistently higher than that of the dry particles, although differences were not quite statistically significant when measurements were performed at ambient conditions. Using humidity control resulted in torque values for wet particles of 1900 uNm and 900 uNm for dry particles. Finally, the friction coefficient was calculated as 0.23 for wet particles and 0.11 for dry particles when humidity was controlled. These frictions coefficients agreed with values for wood reported in the literature. Overall, controlling humidity is strongly recommended to quantify the range of friction for particles that uptake water, including granular systems from biomass to food to powders.

biomass↗

A quantitative assessment of the model form error of friction models across different interface representations for jointed structures

Hysteretic models are widely used to model frictional interactions in joints to recreate experimental behavior. However, it is unclear which models are best suited for fitting or predicting the responses of structures. Here, the present study evaluates 26 friction model/interface representation combinations to quantify the model form error. A Quasi-Static Modal Analysis approach (termed Rayleigh Quotient Nonlinear Modal Analysis) is adopted to calculate the nonlinear system response, and a Multi-Objective Optimization is solved to fit experimental data of the first mode of the Brake-Reuß Beam. Optimized parameters from the first mode are applied to the second and third bending modes to quantify the predictive ability of the models. Formulations for both tracing full hysteresis loops and recreating hysteresis loops from a single loading curve (Masing assumptions) are considered. Smoothly varying models applied to a five patch representation showed the highest flexibility (for fitting mode 1) and good predictive potential (for modes 2 and 3). For a second formulation, which uses 152 frictional elements to represent the interface, the physically motivated spring in series with a Coulomb slip model (elastic dry friction) has high error for fitting mode 1 and performs near the middle for predicting higher modes. For both interface representation, the best fit models are not the most physical, but rather the ones with the most parameters (as expected); however, the more physical models perform somewhat better for predicting the higher modes.

42 ENGINEERING↗

Recurrence analysis of friction based dry-couplant ultrasonic Lamb waves in plate-like structures

Here, in this study, the effect of friction on the generation of dry-coupled Lamb waves is experimentally investigated. Recurrence analysis is performed to analyze the complex behavior of friction based dry-coupled Lamb waves. In particular, the effect of the normal force, which is necessary for a stronger dry-coupled Lamb wave generation and the friction, on the transmission of mechanical energy and determinism characteristics of Lamb waves are investigated. The results verify that larger friction coefficient and friction force are crucial for generation and propagation of strong Lamb waves supporting the fact that the main mechanism to transfer mechanical energy using dry-couplant is friction. The sensitivity of Lamb waves to the friction coefficient, highlights the importance of designing specific pads with respect to condition of the surface. Besides, the results show that the normal force and friction coefficient can change the determinism characteristics behavior of multimode Lamb waves. Furthermore, it is shown that the determinism value is sensitive to the friction coefficient and normal force. A similar trend is observed in the determinism values and friction coefficient. In general, a smaller friction coefficient indicates smaller determinism value. Additionally, it is shown that a normal load can change the behavior of a system, as observed from recurrence plots, owing to changes in the Lamb waves trajectories in the phase-space domain. In addition, it is shown that recurrence plots enable the detection of mode transitions in multimode Lamb waves. Recurrence analysis is a complementary tool to frequency domain methods for accurate analysis of multimode Lamb waves behavior.

42 ENGINEERING↗

A prediction model of failure threshold for shear deformation in a Zr-based bulk metallic glass

The failure of bulk metallic glasses (BMGs) during plastic deformation at room temperature is abrupt and instantaneous, while the analysis of precursor information based on avalanche events helps predict catastrophic failure. An acoustic emission (AE) signal can provide accurate precursor information for material failure, due to its sensitive and high fast calculation ability. In the current study, AE monitoring tests are carried out during uniaxial compression tests of BMGs at different strain rates. The AE experimental failure threshold, E max , is proposed on the basis of AE cumulative energy, which reflects the intensity of damage evolution at different loading conditions. Compared with the critical shear band velocity (CSBV) associated with stick-slip dynamics of serrated flow, E max is a more sensitive failure parameter since it is connected with the local microscopic changes that occur during the material response process. Here, the E max is obtained prior to reaching the CSBV since the calculation of these two avalanches analysis focuses on the different stages of shear band growth. In particular, AE events are related to the “dry” friction process in the first stage, however, the CSBV is responsible for the “viscous” glide in the second stage. Therefore, Emax is not affected by the complex interactions between the shear bands during the stick-slip process. The maximum avalanche of serrated flow, S max , is proposed as the experimental failure threshold, which depends on the applied strain rate as S max ~ $\dot{ε}$ –λ . According to the relationship of E max and S max , the theoretical failure threshold, E max , follows a criterion E max = 2545$\dot{ε}$ –λ - 4468, where λ is equivalent to 0.15 for this work. Finally, combining the different calculations and AE measurements, this model gives new insights to predict the deformation failure behavior of Zr-based BMGs.

36 MATERIALS SCIENCE↗

Circuit Modelling of the Mechanical-Motion-Rectifier for Electrical Simulation of Ocean Wave Power Take-off

As is the case with several other mechanical power takeoffs (PTOs), the mechanical-motion-rectifier (MMR) based PTO consists of components such as one-way clutches, gears, a ball screw, mechanical couplings, and a generator. Equivalent circuit models have been created in this paper to describe the dry frictions, viscous damping, and mechanical compliances in these components, so the non-ideal efficiency and nonlinear force of the PTO can be predicted in electrical simulations by integrating these sub-circuit models. The circuit model is simplified, and its parameters are categorized as dc and ac unknowns. The dc and ac tests on the PTO are performed sequentially to extract two sets of parameters through linear regression or nonlinear curve fitting. Then, the model is validated through its prediction capability over 25 test conditions on input forces, output voltages, and efficiencies, with correlation coefficients of 0.9, 0.98, and 0.981, respectively.

42 ENGINEERING↗

A FEASIBILITY STUDY ON CRACK REPAIR IN AUSTENITIC STAINLESS STEEL DRY STORAGE CANISTERS USING ISOTHERMAL FRICTION STIR WELDING

In recent time, solid state crack repair techniques in spent nuclear fuel dry storage canisters (SNF-DSC) have garnered significant interest. Plates of austenitic stainless steels are usually arc welded to fabricate the cylindrical canisters which are prone to chloride-induced stress corrosion cracking. Friction stir welding (FSW) is considered to be a potential candidate for damage repair. In this work, electrical discharge machining was used to simulate cracks in 304L stainless steel plates of 12.7 mm thickness. Subsequently, isothermal FSW was carried out at two different temperatures (725 and 825°C) in order to repair the simulated crack. Microstructure-mechanical property correlations in FSWed plates were studied in detail. Significant grain refinement observed in the stir zone (SZ) was attributed to dynamic recrystallization occurring during FSW. A comparison of Vickers microhardness showed higher hardness and homogeneity in the 725°C SZ than its 825°C counterpart. The fraction of S3 boundary is found to be low in the SZ as compared to base metal (BM). Yield strength of the joints was found to be approximately 100 MPa higher than that of the BM accompanied by a drop in ductility by a factor of 2. Residual stress profile across 825°C weld was measured using x-ray diffraction.

Bhattacharyya, Madhumanti↗

Friction Stir Processed Repair Welding of Dry Storage Canisters and Mitigation Strategies: Effect of Engineered Barrier Layer on Environmental Degradation

The proposed project aims to develop a friction sir based repair technique to heal cracks of stainless steel dry storage canisters (DSCs), created by the effect of stress corrosion cracking (SCC). In real service conditions, the welded parts of the canisters become prone to SCC under exposure to aggressive chemical environment. The focus of the project is on developing a mitigation strategy that can be implemented for countering SCC in DSCs following a two-pronged approach: (i) apply friction stir processing (FSP) as a crack repair technique while creating compressive residual stresses at the canister material surface, thus improving resistance against SCC; (ii) add molybdenum and/or nitrogen by friction stir based alloying process to create compositions that improve pitting resistance and thus enhance resistance against SCC. The specific project objectives are listed below: • Investigate FSW of 304L SS a potential repair welding technique of dry storage canisters; • Optimize the FSW parameters to introduce surface compressive stress profiles in the weldments; • Develop a FSP method to surface alloy the 304L with nitrogen and Mo by adding CrN and Mo powders; • Evaluate the surface compressive residual stress profile during FSW and FSP processes; • Evaluate the localized corrosion resistance of the FSW and FSP samples as a function of temperature, chloride concentration, and surface alloy composition; • Evaluate the SCC behavior of the FSW and FSP samples as a function of stress, chloride concentration, and temperature at different surface chemistries and induced residual stress profiles.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Physical Properties of Moist, Fermented Corn Kernels

A novel approach to producing corn stover biomass feedstock has been investigated. In this approach, corn grain and stover are co-harvested at moisture contents much less than typical corn silage. The grain and stover are conserved together by anaerobic storage and fermentation and then separated before end use. When separated from the stover, the moist, fermented grain had physical characteristics that differ from typical low-moisture, unfermented grain. A comprehensive study was conducted to quantify the physical properties of this moist, fermented grain. Six corn kernel treatments, either fermented or unfermented, having different moisture contents, were used. Moist, fermented kernels (26 and 36% w.b. moisture content) increased in size during storage. The fermented kernels’ widths and thicknesses were 10% and 15% greater, respectively, and their volume was 28% greater than the dry kernels (15% w.b.). Dry basis particle density was 9% less for moist, fermented kernels. Additionally, the dry basis bulk density was 29% less, and the dry basis hopper-discharged mass flow rate was 36% less. Moist, fermented grain had significantly greater kernel-to-kernel coefficients of friction and angles of repose compared to relatively dry grain. The friction coefficient on four different surfaces was also significantly greater for fermented kernels. Fermented corn kernels had lower individual kernel rupture strengths than unfermented kernels. These physical differences must be considered when designing material handling and processing systems for moist, fermented corn grain.

09 BIOMASS FUELS↗

Chloride-Induced Stress Corrosion Cracking of Friction Stir-Welded 304L Stainless Steel: Effect of Microstructure and Temperature

Dry storage canisters of used nuclear fuels are fabricated using SUS 304L stainless steel. Chloride-induced stress corrosion cracking (CISCC) is one of the major failure modes of dry storage canisters. The cracked canisters can be repaired by friction stir welding (FSW), a low-heat input ‘solid-phase’ welding process. It is important to evaluate the ClSCC resistance of the friction stir welded material. Stress corrosion cracking (SCC) studies were carried out on mill-annealed base materials and friction stir welded 304L stainless U-bend specimens in 3.5% NaCl + 5 N H2SO4 solution at room temperature and boiling MgCl2 solution at 155 °C. The engineering stress on the outer fiber of the FSW U-bend specimen was ~60% higher than that of the base metal (BM). In spite of the higher stress level of the FSW, both materials (FSW and BM) showed almost similar SCC failure times in the two different test solutions. The SCC occurred in the thermo-mechanically affected zone (TMAZ) of the FSW specimens in the 3.5% NaCl + 5 N H2SO4 solution at room temperature, while the stirred zone (SZ) was relatively crack-free. The failure occurred at the stirred zone when tested in the boiling MgCl2 solution. Hydrogen reduction was the cathodic reaction in the boiling MgCl2 solution, which promoted hydrogen-assisted cracking of the heavily deformed stirred zone. The emergence of the slip step followed by passive film rupture and dissolution of the slip step could be the SCC events in the 3.5% NaCl + 5 N H2SO4 solution at room temperature. However, the slip step height was not sufficient to cause passivity breakdown in the fine-grained SZ. Therefore, the SCC occurred in the partially recrystallized softer TMAZ. Overall, the friction-stirred 304L showed higher tolerance to ClSCC than the 304L base metal.

304L austenitic stainless steel↗

Friction and wear of nuclear graphite exposed to molten FLiNaK salt environment

This report formally documents the completion of the Advanced Reactor Technologies Level 3 Milestone (M3TG-25OR0501104), “Initiate graphite wear studies of graphite samples exposed to molten salt environment,” due August 1, 2025. The report summarizes the ongoing activities aimed at characterizing the friction and wear behavior of graphite in molten LiF–NaF–KF (FLiNaK) salt environment. The wear and friction behavior of self-mated ET-10 nuclear graphite were tested at varying temperatures (550°C and 650°C), contact loads (40 and 80 N) and sliding speeds (1 and 10 mm/s) in a controlled argon environment. The results were compared to the wear and friction behavior of the same graphite material in a dry argon environment. This report presents initial studies on the friction and wear behavior of graphite in sliding contact mode, with future work focused on investigating the graphite matrix materials, as well as rolling and impact contact modes. The outcomes of this report could provide insights into assessing the integrity of the graphitic components of pebble-bed fluoride salt–cooled high-temperature reactors (PB-FHRs) to enhance their safe operation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Friction Experiment Data Analysis

The Spent Fuel Waste Disposition (SFWD) program under the U.S. Department of Energy (DOE) is planning a seismic shake table test of full-scale dry storage systems of spent nuclear fuel (SNF) to close the gap related to the seismic loads on the fuel assemblies in dry storage systems. This test will allow for quantifying the strains and accelerations on surrogate fuel assembly during representative earthquakes. A concrete layer will be installed on the shake table before the test to simulate conditions representative of an ISFSI pad. In the shake table tests with the vertical cask, the cask will be free-standing because this is representative of all, except two, ISFSIs in the U.S. with vertical dry storage casks. The static and dynamic friction coefficients between the steel bottom of the cask and the concrete layer on the shake table are important parameters that will affect cask behavior during the test. These parameters must be known for the pre- and post-test modelling, data analysis, and model validation. The friction experiment was performed at the Engineering Department of the University of New Mexico (UNM) to determine the friction coefficients between a steel plate with the same finish as the bottom of the vertical cask manufactured for the test and different concrete surfaces. In this experiment the steel plate was fixed and the concrete sample was pulled over the plate with a constant displacement rate using an MTS machine. This allowed for collecting continuous horizontal force data over the length of the steel plate. Four displacement rates and three vertical loads were used. The tests were performed with four concrete blocks with different degrees of the surface roughness - light sandblast, light to medium sandblast, medium bush hammer, and heavy sandblast. The total number of tests was 48. The data were used to calculate static and dynamic friction coefficients.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Pitting behavior of friction stir repair-welded 304L stainless steel in 3.5% NaCl solution at room temperature: role of grain and defect structures

Stainless steel (SS) canisters used for storing spent nuclear waste are prone to chloride-induced stress corrosion cracking. Friction stir welding (FSW), being a low heat input process, can be used for repair welding of these canisters. In this study, an artificial crack was introduced on the 304L SS coupons by an electric discharge machining process. The artificial crack was repair-welded by FSW by maintaining the tool temperature a constant at two levels (725 and 825 °C). Friction stirring significantly reduced the grain size of the stirred zone (SZ) from about 47 to 2–4 μm. The fraction of low-angle grain boundaries increased in the SZ from 2 to 37–43%. Here, on the other hand, the fraction of special grain boundaries (Σ3 and Σ9) that was ~ 50% in the base metal reduced to < 10% in the SZ. During friction stirring, the oxide layer of artificial crack was broken and aligned to form a spiral defect called lazy-S structure. All these microstructural changes affected the corrosion behavior of the FSW specimens when tested in 3.5% NaCl at room temperature using cyclic polarization, chronoamperometry, and electrochemical impedance spectroscopy. The FSW specimens showed lower polarization resistance and lower transpassive potential than those of the base metal specimens. However, the pitting protection potentials of the FSW specimens were higher than that of the base metal. The pitting behavior of the FSW specimens was influenced more by the preferential attack on the lazy-S region than by passive film breakdown. The flat band potentials of the passive film formed on the FSW specimens were more positive than that of base metal. The charge carrier density of passive film formed on the FSW specimens was higher than that of the base metal. The higher fraction of low-angle grain boundaries present in the FSW specimens could supply more number of misorientation dislocations at the metal/film interface which could form anion vacancies by a climb process leading to formation of oxide at these locations without stressing the substrate. Therefore, low-angle boundaries are considered helpful for formation of stress-free passive films that will be highly stable and enhance both pitting and stress corrosion cracking resistance.

Dry storage canister↗

Production of desensitized, ultrafine PETN powder

Pentaerythritol tetranitrate (PETN) is a widely studied high explosive (HE), most commonly used in detonator applications. In this work, we use a spray drying technique to manufacture a new “nano-powder” morphology of PETN. The spray dried PETN is several orders of magnitude smaller in particle size than traditionally prepared PETN powders. The spray dried PETN has a mostly spherical and smooth morphology, while traditional crystalline PETN typically has sharp edges and crystal facets. Small-scale sensitivity tests including drop-weight impact, friction, and electrostatic discharge (ESD) indicate the spray dried PETN is less sensitive than traditionally used forms of PETN powders. Furthermore, we also observed no changes in chemical properties (melt temperature and onset of decomposition) after spray drying, and the material remains in the tetragonal, crystalline phase.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Perspectives of 2D MXene Tribology

Abstract The large and rapidly growing family of 2D early transition metal carbides, nitrides, and carbonitrides (MXenes) raises significant interest in the materials science and chemistry of materials communities. Discovered a little more than a decade ago, MXenes have already demonstrated outstanding potential in various applications ranging from energy storage to biology and medicine. The past two years have witnessed increased experimental and theoretical efforts toward studying MXenes’ mechanical and tribological properties when used as lubricant additives, reinforcement phases in composites, or solid lubricant coatings. Although research on the understanding of the friction and wear performance of MXenes under dry and lubricated conditions is still in its early stages, it has experienced rapid growth due to the excellent mechanical properties and chemical reactivities offered by MXenes that make them adaptable to being combined with other materials, thus boosting their tribological performance. In this perspective, the most promising results in the area of MXene tribology are summarized, future important problems to be pursued further are outlined, and methodological recommendations that could be useful for experts as well as newcomers to MXenes research, in particular, to the emerging area of MXene tribology, are provided.

2D materials↗

Electrodeposited Mo x S y O z /Ni Tribological Coatings

Deposition of molybdenum disulfide (MoS 2 ) coatings using physical vapor deposition (PVD) and mechanical burnishing has been widely assessed for solid lubricants in space applications but still suffers from line-of-sight constraints on complex geometries. Here, we highlight one of the first demonstrations of electrodeposited Mo x S y O z and Mo x S y O z /Ni thin-film coatings from aqueous solutions of ammonium tetrathiomolybdate for solid lubricant applications and their remarkable ability to provide low coefficients of friction and high wear resistance. Characterization of the coating morphology shows amorphous microstructures with a high oxygen content and cracking upon drying. Even so, electrodeposited Mo x S y O z can achieve low steady-state coefficients of friction (μ ∼ 0.05–0.06) and wear rates (2.6 × 10 –7 mm 3 /(N m)) approaching those of physical vapor deposited coatings (2.3 × 10 –7 mm 3 /(N m)). Additionally, we show that adding dopants such as nickel increased the wear rate (7.5 × 10 –7 mm 3 /(N m)) and initial coefficient of friction (μ i = 0.23) due to compositional modifications such as dramatic sub-stoichiometry (S/Mo ∼ 1) and expression of a NiO x surface layer, although doping did reduce the degree of cracking upon drying.

Babuska, Tomas F.↗

Experimental Investigation of Elastodynamic Nonlinear Response of Dry Intact, Fractured and Saturated Rock

Nonlinear elastodynamic response of fractured rocks carries crucial information on fracture features that can be exploited to forecast flow properties, friction constitutive behavior and poromechanical response. Well-controlled laboratory experiments are designed to measure the nonlinear elastodynamic response of Westerly granite in three states: dry intact, dry fractured and saturated fractured. We study the effect of fracturing and saturation in modifying the elastodynamic response of the rock. Each sample is tested at a normal stress level of 15 MPa. We measure the elastodynamic response of an intact L-shaped sample of Westerly Granite subjected to normal stress oscillations of prescribed amplitudes (0.2–1 MPa) and frequencies (0.1, 1, 10 Hz). Ultrasonic waves transmitted across the sample are used to monitor the evolution of wave velocity before, during and after dynamic stressing. Furthermore, the nonlinearity of the elastodynamic response is measured in terms of: (1) the offset in normalized wave velocity; (2) the amplitude of wave velocity fluctuation during the oscillations; and (3) recovery rate of the wave velocity post-oscillation. We observe that the three nonlinearity parameters show a similar trend. Irrespective of the parameter, the nonlinearity measures higher for sample in dry-intact condition than that for dry-fractured and the saturated-fractured sample exhibits smaller nonlinearity than the dry-fractured sample. As expected, the saturated sample exhibits less nonlinearity than the dry intact and fractured samples due to the presence of interstitial fluid and the resulting increased interface stiffness. Conversely, the dry intact rock shows a higher nonlinearity than the dry fractured. We use numerical simulations to show that the presence of fracture significantly alters the strain distribution across the bulk of the sample and only the contacting asperities are highly strained, thus resulting in a decrease in the measured elastodynamic nonlinearity.

58 GEOSCIENCES↗

Lignetics CRADA closeout report

Lignetics is one of the leading domestic producers of wood pellet fuels used for domestic heating. The company also produces pellets for other applications including animal bedding. The primary feedstock used for the production of Lignetics products is woody biomass. To improve the economics of pellet production, Lignetics is evaluating advanced preprocessing technologies developed by researchers at INL. In the proposed project, INL and Lignetics will work collaboratively to assess the feasibility of integrating INL’s advanced preprocessing technologies (fractional milling, high moisture pelleting and low temperature drying) in Lignetics production facilities. The successful completion of the project relies on the integration of the fractional milling and high moisture pelleting (HMP) process and low temperature drying to improve the economics of woody biomass pellet production for use in biofuel and bioproduct applications. In the HMP process, the biomass loses some moisture during compression and extrusion through the pellet die due frictional heat developed. Also, as pellets have a definite size and shape, they can be further dried in low temperature grain or belt dryers. Belt dryers are better suited to take advantage of low-grade and waste heat because they operate at lower temperatures than rotary dryers (Tumuluru et al.) Rotary dryers, for example, typically require inlet temperatures of 260°C, but more optimally operate around 400°C. In contrast, the inlet temperature of a belt dryer, such as a commercially available vacuum dryer, can be as low as 10°C above the ambient temperature, although more typically they operate at higher temperatures, between 90°C and 200°C. Because of their lower temperature operation, fire hazards and emissions to the air are lower for belt dryers in addition to reducing drying and overall pelleting costs, INL’s technology also has potential to reduce emissions at Lignetics facilities.

09 BIOMASS FUELS↗