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Linking process and structure in the friction stir scribe joining of dissimilar materials: A computational approach with experimental support
We present that friction stir welding (FSW) is a popular technique to join dissimilar materials in numerous applications. The solid state nature of the process enables joining materials with strikingly different physical properties. For welds in lap configuration, an enhancement to this technology is made by introducing a short, hard insert, referred to as a cutting-scribe, at the bottom of the tool pin. The cutting-scribe induces deformation in the bottom plate which leads to the formation of mechanical interlocks or hook like structures at the interface of two materials. A thermo-mechanical computational model employing a coupled Eulerian-Lagrangian approach is developed to quantitatively capture the morphology of these interlocks during the FSW process. Simulations using this model are validated by experimental observations. In conclusion, the identified interface morphology coupled with the predicted temperature field from this process–structure model can be used to estimate the post-weld microstructure and joint strength.
Operando formation of an ultra-low friction boundary film from synthetic magnesium silicon hydroxide additive
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Field-gradient partitioning for fracture and frictional contact in the material point method: Field-gradient partitioning for fracture and frictional contact in the material point method [Fracture and frictional contact in material point method using damage-field gradients for velocity-field partitioning]
Contact and fracture in the material point method require grid-scale enrichment or partitioning of material into distinct velocity fields to allow for displacement or velocity discontinuities at a material interface. We present a new method which a kernel-based damage field is constructed from the particle data. The gradient of this field is used to dynamically repartition the material into contact pairs at each node. Our approach avoids the need to construct and evolve explicit cracks or contact surfaces and is therefore well suited to problems involving complex 3-D fracture with crack branching and coalescence. A straightforward extension of this approach permits frictional ‘self-contact’ between surfaces that are initially part of a single velocity field, enabling more accurate simulation of granular flow, porous compaction, fragmentation, and comminution of brittle materials. Finally, numerical simulations of self contact and dynamic crack propagation are presented to demonstrate the accuracy of the approach.
Investigation of Shear-Thinning Behavior on Film Thickness and Friction Coefficient of Polyalphaolefin Base Fluids With Varying Olefin Copolymer Content
This study investigates the rheological properties, elastohydrodynamic (EHD) film-forming capability, and friction coefficients of low molecular mass poly-alpha-olefin (PAO) base stocks with varying contents of high molecular mass olefin copolymers (OCPs) to assess their shear stability and their potential for energy-efficient lubrication. Several PAO-OCP mixtures were blended in order to examine the relationship between their additive content and tribological performance. Gel permeation chromatography (GPC) and nuclear magnetic resonance (NMR) spectroscopy were used to characterize the molecular masses and structures, respectively. Density, viscosity, EHD film thickness, and friction were measured at 303 K, 348 K, and 398 K. Film thickness and friction were studied at entrainment speeds relevant to the boundary, mixed, and full-film lubrication regimes. The PAO-OCP mixtures underwent temporary shear-thinning resulting in decreases in film thickness and hydrodynamic friction. These results demonstrate that the shear characteristics of PAO-OCP mixtures can be tuned with the OCP content and provide insight into the effects of additives on EHD characteristics.
Experimental evidence for dynamic friction on rock fractures from frequency-dependent nonlinear hysteresis and harmonic generation: Low-Frequency Torsional Dynamic Friction
Frictional properties affect the propagation of high-amplitude seismic waves across rock fractures and faults. Laboratory evidence suggests that these properties can be measured in active seismic surveys, potentially offering a route to characterizing friction in situ. Here, we present experimental results from a subresonance torsional modulus and attenuation apparatus that utilizes micron-scale sinusoidal oscillations to probe the nonlinear stress-strain relation at a range of strain amplitudes and rates. Nonlinear effects are further quantified using harmonic distortion; however, time series data best illuminate underlying physical processes. The low-frequency stress-strain hysteretic loops show stiffening at the sinusoid's static ends, but stiffening is reduced above a threshold frequency. This shape is determined by harmonic generation in the strain; the stress signal has no harmonics, confirming that the fractured sample is the source of the nonlinearity. These qualitative observations suggest the presence of rate-dependent friction and are consistent between fractures in three different rock types. We propose that static friction at the low strain rate part of the cycle, when given sufficient “healing” time at low oscillation frequencies, causes this stiffening cusp shape in the hysteresis loop. While rate-and-state friction is commonly used to represent dynamic friction, it cannot capture static friction or negative slip velocities. So we implement another dynamic friction model, based on the work of Dahl, which describes this process and produces similar results. Since the two models have a similar form, parameterizations of field data could constraint fault model inputs, such as specific location velocity strengthening or weakening properties.
Frictional properties of Opalinus Clay: influence of humidity, normal stress and grain size on frictional stability
SUMMARY The Opalinus Clay (OPA) is a clay-rich formation considered as a potential host rock for radioactive waste repositories and as a caprock for carbon storage in Switzerland. Its very low permeability (10−19 to 10−21 m2) makes it a potential sealing horizon, however the presence of faults that may be activated during the lifetime of a repository project can compromise the long-term hydrological confinement, and lead to mechanical instability. Here, we have performed laboratory experiments to test the effect of relative humidity (RH), grain size (g.s.) and normal stress on rate-and-state frictional properties and stability of fault laboratory analogues corresponding to powders of OPA shaly facies. The sifted host rock powders at different grain size fractions (<63 μm and 63 < g.s. < 125 μm), at room (∼25 per cent) and 100 per cent humidity, were slid in double-direct shear configuration, under different normal stresses (5–70 MPa). We observe that peak friction, μpeak and steady-state friction, μss, depend on water vapour content and applied normal stress. Increasing relative humidity from ∼25 per cent RH (room humidity) to 100 per cent RH causes a decrease of frictional coefficient from 0.41 to 0.35. The analysis of velocity-steps in the light of rate-and-state friction framework shows that the stability parameter (a–b) is always positive (velocity-strengthening), and it increases with increasing sliding velocity and humidity. The dependence of (a–b) on slip rate is lost as normal stress increases, for each humidity condition. By monitoring the variations of the layer thickness during the velocity steps, we observe that dilation (Δh) is directly proportional to the sliding velocity, decreases with normal stress and is unaffected by humidity. Microstructural analysis shows that most of the deformation is accommodated within B-shear zones, and the increase of normal stress (σn) promotes the transition from strain localization and grain size reduction to distributed deformation on a well-developed phyllosilicate network. These results suggest that: (1) the progressive loss of velocity dependence of frictional stability parameter (a–b) at σn > 35 MPa is dictated by a transition from localized to distributed deformation and (2) water vapour content does not affect the deformation mechanisms and dilation, whereas it decreases steady-state friction (μss), and enhances fault stability.
Modeling and data analysis of the NASA-WSTF frictional heating apparatus - Effects of test parameters on friction coefficient
A theoretical model is being developed jointly by the NASA White Sands Test Facility (WSTF) and the University of California at Santa Barbara (UCSB) to analyze data generated from the WSTF frictional heating test facility. Analyses of the data generated in the first seconds of the frictional heating test are shown to be effective in determining the friction coefficient between the rubbing interfaces. Different friction coefficients for carobn steel and Monel K-500 are observed. The initial condition of the surface is shown to affect only the initial value of the friction coefficient but to have no significant influence on the average steady-state friction coefficient. Rotational speed and the formation of oxide film on the rotating surfaces are shown to have a significant effect on the friction coefficient.
Evaluation of two transport aircraft and several ground test vehicle friction measurements obtained for various runway surface types and conditions. A summary of test results from joint FAA/NASA Runway Friction Program
Tests with specially instrumented NASA Boeing 737 and 727 aircraft together with several different ground friction measuring devices were conducted for a variety of runway surface types and conditions. These tests are part of joint FAA/NASA Aircraft/Ground Vehicle Runway Friction Program aimed at obtaining a better understanding of aircraft ground handling performance under adverse weather conditions and defining relationships between aircraft and ground vehicle tire friction measurements. Aircraft braking performance on dry, wet, snow and ice-covered runway conditions is discussed as well as ground vehicle friction data obtained under similar runway conditions. For a given contaminated runway surface condition, the correlation between ground vehicles and aircraft friction data is identified. The influence of major test parameters on friction measurements such as speed, test tire characteristics, type and amount of surface contaminant, and ambient temperature are discussed. The effect of surface type on wet friction levels is also evaluated from comparative data collected on grooved and ungrooved concrete and asphalt surfaces.
Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock
Abstract Titanium and its alloys are used in aviation and automobile industries due to their remarkable strength to weight ratio, but machining loss commonly is high with ~ 80 wt% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4 V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting the rotation rate and feed rate, to process the billets near 1000 °C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of directly recycling Ti-6Al-4 V scrap into extruded wire.
Joining thick section aluminum to steel with suppressed FeAl intermetallic formation via friction stir dovetailing
A new solid-phase technique called friction stir dovetailing (FSD) has been developed for joining thick section aluminum to steel. In FSD, mechanical interlocks are formed at the aluminum-steel interface and are reinforced by metallurgical bonds where intermetallic growth has been uniquely suppressed. Lap shear testing shows superior strength and extension at failure compared to popular friction stir approaches where metallurgical bonding is the only joining mechanism. High resolution microscopy revealed the presence of a 40-70 nm interlayer having a composition of 76.4 at% Al, 18.4 at% Fe, and 5.2 at% Si, suggestive of limited FeAl3 intermetallic formation.
Acid Treatment of Diamond-Like Carbon Surfaces for Enhanced Adsorption of Friction Modifiers and Friction Performance
Diamond-like carbon (DLC) is a class of amorphous carbon materials used as wear-resistant coatings in tribo-components. The chemical inertness of DLC surfaces, while important in many applications, makes them incompatible with additives in commercial lubricants. Specifically, DLC surfaces do not permit strong adsorption of friction modifier molecules. This study aims at improving the adsorption of these friction modifier molecules on DLC surfaces through an acid treatment. Water contact angle measurements show that such a treatment results in improved hydrophilicity of the DLC. XPS analysis demonstrates 50% increase in the uptake of ArmeenT, an organic friction modifier, on DLC after the acid treatment. This increased ArmeenT adsorption is accompanied by marked decrease in friction in micro-scale friction experiments.
Ultralow Boundary Lubrication Friction by Three-Way Synergistic Interactions among Ionic Liquid, Friction Modifier, and Dispersant
Interactions among antiwear additives (AWs), friction modifiers (FMs), and dispersant in a lubricating oil are critical for tribological performance. This study investigates compatibilities of three oil-soluble ionic liquids (ILs, candidate AWs) with an FM, molybdenum dithiocarbamate (MoDTC), and a dispersant, polyisobutene succinimide (PIBSI) under boundary lubrication. Either synergistic or antagonistic effects were observed depending on the IL’s chemistry. Adding an aprotic phosphonium–alkylphosphate or phosphonium–alkylphosphinate IL into the oil containing MoDTC and PIBSI had detrimental impact on the friction and wear behavior. PIBSI was found to preferably interact/react with the aprotic IL to lose its ability of suspending MoDTC and to partially consume or even deplete the IL. In contrast, a protic ammonium–alkylphosphate IL seemed to be able to coexist with PIBSI and work synergistically with MoDTC, yielding a sustainable, ultralow boundary friction. A three-stage tribochemical process is proposed to explain how this IL + MoDTC pair interacts with the contact surface to form a chemically reacted, wear-protective tribofilm supporting a physically adsorbed, friction-reducing film on top. We report this study provides fundamental insights of the compatibilities among three common lubricant components, antiwear, friction modifier, and dispersant, which can be used to guide future lubricant development.
Friction- and Wear-Reducing Properties of Multifunctional Small Molecules
Nitrogen- and oxygen-containing compounds were designed and synthesized, and their tribological performance as multifunctional base oils (MFBOs) for internal combustion engine applications was evaluated. Two of the compounds displayed good rheology without the addition of polymeric viscosity modifiers, with a high viscosity index (VI) above 200.Additionally, all three MFBOs had lower coefficients of friction when compared to well established and accepted benchmarks, and demonstrated wear improvement by a factor of 5.5 to 70 compared to either of the benchmarks. Moreover, the compounds were easily synthesized in one step from commercial intermediates or starting materials. This work demonstrates that careful design of a single molecule might provide the functions of base oil, viscosity modifiers (or viscosity index improvers), anti-wear and friction reducing additives.
Linking microstructural evolution and macro-scale friction behavior in metals [Predicting the friction behavior of metals using a microstructural evolution model]
A correlation is established between the macro-scale friction regimes of metals and a transition between two dominant atomistic mechanisms of deformation. Metals tend to exhibit bi-stable friction behavior—low and converging or high and diverging. These general trends in behavior are shown to be largely explained using a simplified model based on grain size evolution, as a function of contact stress and temperature, and are demonstrated for self-mated pure copper and gold sliding contacts. Specifically, the low-friction regime (where µ < 0.5) is linked to the formation of ultra-nanocrystalline surface films (10–20 nm), driving toward shear accommodation by grain boundary sliding. Above a critical combination of stress and temperature—demonstrated to be a material property—shear accommodation transitions to dislocation dominated plasticity and high friction, with µ > 0.5. We utilize a combination of experimental and computational methods to develop and validate the proposed structure–property relationship. As a result, this quantitative framework provides a shift from phenomenological to mechanistic and predictive fundamental understanding of friction for crystalline materials, including engineering alloys.
Friction and wear of TPS fibers: A study of the adhesion and friction of high modulus fibers
The adhesional and frictional forces between filaments in a woven fabric or felt, strongly influenced the processability of the fiber and the mechanical durability of the final product. Even though the contact loads between fibers are low, the area of contact is extremely small giving rise to very high stresses; principally shear stresses. One consequence of these strong adhesional and frictional forces is the resistance of fibers to slide past each other during weaving or when processed into nonwoven mats or felts. Furthermore, the interfiber frictional forces may cause surface damage and thereby reduce the fiber strength. Once formed into fabrics, flexural handling and manipulation of the material again causes individual filaments to rub against each other resulting in modulus, brittle fibers such as those used in thermal protection systems (TPS). The adhesion and friction of organic fibers, notably polyethylene terephthalate (PET) fibers, have been extensively studied, but there has been very little work reported on high modulus inorganic fibers. An extensive study was made of the adhesion and friction of flame drawn silica fibers in order to develop experimental techniques and a scientific basis for data interpretation. Subsequently, these methods were applied to fibers of interest in TPS materials.
A vacuum (10(exp -9) Torr) friction apparatus for determining friction and endurance life of MoSx films
The first part of this paper describes an ultrahigh vacuum friction apparatus (tribometer). The tribometer can be used in a ball-on-disk configuration and is specifically designed to measure the friction and endurance life of solid lubricating films such as MoS(x) in vacuum at a pressure of 10 exp -7 Pa. The sliding mode is typically unidirectional at a constant rotating speed. The second part of this paper presents some representative friction and endurance life data for magnetron sputtered MoS(x) films (110 nm thick) deposited on sputter-cleaned 440 C stainless-steel disk substrates, which were slid against a 6-mm-diameter 440 C stainless-steel bearing ball. All experiments were conducted with loads of 0.49 to 3.6 N (average Hertzian contact pressure, 0.33 to 0.69 GPa), at a constant rotating speed of 120 rpm (sliding velocity ranging from 31 to 107 mm/s due to the range of wear track radii involved in the experiments), in a vacuum of 7 x 10 exp -7 Pa and at room temperature. The results indicate that there are similarities in friction behavior of MoS(x) films overs their life cycles regardless of load applied. The coefficient of friction (mu) decreases as load W increases according to mu = kW exp -1/3. The endurance life E of MoS(x) films decreases as the load W increases according to E = KW exp -1.4 for the load range. The load- (or contract-pressure-) dependent endurance life allows us to reduce the time for wear experiments and to accelerate endurance life testing of MoS(x) films. For the magnetron-sputtered MoS(x) films deposited on 440 C stainless-steel disks: the specific wear rate normalized to the load and the number of revolutions was 3 x 10 exp -8 mm exp 3/N-revolution; the specific wear rate normalized to the load and the total sliding distance was 8 x 10 exp -7 mm exp 3/N-m; and the nondimensional wear coefficient of was approximately 5 x 10 exp -6. The values are almost independent of load in the range 0.49 to 3.6 N (average Hertzian contact pressures of 0.33 to 0.69 GPa).