Michael E. Dahl

Friction stir spot welding of DP780 carbon steel

Abstract Friction stir spot welds were made in uncoated and galvannealed DP780 sheets using polycrystalline boron nitride stir tools. The tools were plunged at either a single continuous rate or in two segments consisting of a relatively high rate followed by a slower rate of shorter depth. Welding times ranged from 1 to 10 s. Increasing tool rotation speed from 800 to 1600 rev min–1 increased strength values. The 2-segment welding procedures also produced higher strength joints. Average lap shear strengths exceeding 10·3 kN were consistently obtained in 4 s on both the uncoated and the galvannealed DP780. The likelihood of diffusion and mechanical interlocking contributing to bond formation was supported by metallographic examinations. A cost analysis based on spot welding in automobile assembly showed that for friction stir spot welding to be economically competitive with resistance spot welding the cost of stir tools must approach that of resistance spot welding electrode tips.

High-pressure hydrogen materials compatibility of piezoelectric films

Hydrogen is well known for materials compatibility issues, including blistering and embrittlement in metals, which are challenges for its use as the next-generation “green” fuel. Beyond metals, hydrogen also degrades piezoelectric materials used as actuators used in direct injection hydrogen internal combustion engines. We present the materials compatibility studies of piezoelectric films in high-pressure hydrogen environments. Absorption of high-pressure hydrogen and composition changes were studied with an elastic recoil detection analysis and Rutherford back-scattering spectrometry in lead zirconate titanate and barium titanate thin films. Hydrogen surface degradation in the form of blistering and Pb mixing was also observed.

Applications of Abrasive-Waterjets for Machining Fatigue-Critical Aerospace Aluminum Parts

Current specifications require AWJ-cut aluminum parts for fatigue critical aerospace structures to go through subsequent processing due to concerns of degradation in fatigue performance. The requirement of secondary process for AWJ-machined parts greatly negates the cost effectiveness of waterjet technology. Some cost savings are envisioned if it can be shown that AWJ net cut parts have comparable durability properties as those conventionally machined. To revisit and upgrade the specifications for AWJ machining of aircraft aluminum, “Dog-bone” specimens, with and without secondary processes, were prepared for independent fatigue tests at Boeing and Pacific Northwest National Laboratory (PNNL). Test results show that the fatigue life is proportional to quality levels of machined edges or inversely proportional to the surface roughness Ra . Even at highest quality level, the average fatigue life of AWJ-machined parts is about 30% shorter than those of conventionally machined counterparts. Between two secondary processes, dry-grit blasting with aluminum oxide abrasives until the striation is removed visually yields excellent result. It actually prolongs the fatigue life of parts at least three times higher than that achievable with conventional machining. Dry-grit blasting is relatively simple and inexpensive to administrate and, equally important, alleviates the concerns of garnet embedment.Copyright

An in situ tensile test apparatus for polymers in high pressure hydrogen

Degradation of material properties by high-pressure hydrogen is an important factor in determining the safety and reliability of materials used in high-pressure hydrogen storage and delivery. Hydrogen damage mechanisms have a time dependence that is linked to hydrogen outgassing after exposure to the hydrogen atmosphere that makes ex situ measurements of mechanical properties problematic. Designing in situ measurement instruments for high-pressure hydrogen is challenging due to known hydrogen incompatibility with many metals and standard high-power motor materials such as Nd. Here we detail the design and operation of a solenoid based in situ tensile tester under high-pressure hydrogen environments up to 42 MPa (6000 psi). Modulus data from high-density polyethylene samples tested under high-pressure hydrogen at 35 MPa (5000 psi) are also reported as compared to baseline measurements taken in air.

Mechanical and electrical properties of low temperature phase MnBi

Low temperature phase (LTP) manganese bismuth (MnBi) is a promising rare-earth-free permanent magnet material due to its high intrinsic coercivity and large positive temperature coefficient. While scientists are making progress on fabricating bulk MnBi magnets, engineers have begun considering MnBi magnets for motor applications. Physical properties other than magnetic ones could significantly affect motor design. Here, we report results of our investigation on the mechanical and electrical properties of bulk LTP MnBi and their temperature dependence. A MnBi ingot was prepared using an arc melting technique and subsequently underwent grinding, sieving, heat treatment, and cryomilling. The resultant powders with a particle size of ∼5 μm were magnetically aligned, cold pressed, and sintered at a predefined temperature. Micro-hardness testing was performed on a part of original ingot and we found that the hardness of MnBi was 109 ± 15 HV. The sintered magnets were subjected to compressive testing at differen...

Machining of Aircraft Titanium With Abrasive-Waterjets for Fatigue Critical Applications

Laboratory tests were conducted to determine the fatigue performance of abrasive-waterjet- (AWJ-) machined aircraft titanium. Dog-bone specimens machined with AWJs were prepared and tested with and without sanding and dry-grit blasting with Al2O3 as secondary processes. The secondary processes were applied to remove the visual appearance of AWJ-generated striations and to clean up the garnet embedment. The fatigue performance of AWJ-machined specimens was compared with baseline specimens machined with CNC milling. Fatigue test results of the titanium specimens not only confirmed our previous findings in aluminum dog-bone specimens but in comparison also further enhanced the fatigue performance of the titanium. In addition, titanium is known to be difficult to cut, particularly for thick parts, however AWJs cut the material 34% faster han stainless steel. AWJ cutting and dry-grit blasting are shown to be a preferred ombination for processing aircraft titanium that is fatigue critical.

Fatigue Testing of Abrasive Water Jet Cut Titanium

Battelle Memorial Institute as part of its U.S. Department of Energy (USDOE) Contract No. DE-AC05-76RL01830 to operate the Pacific Northwest National Laboratory (PNNL) provides technology assistance to qualifying small businesses in association with a Technology Assistance Program (TAP). Qualifying companies are eligible to receive a set quantity of labor associated with specific technical assistance. Having applied for a TAP agreement to assist with fatigue characterization of Abrasive Water Jet (AWJ) cut titanium specimens, the OMAX Corporation was awarded TAP agreement 09-02. This program was specified to cover dynamic testing and analysis of fatigue specimens cut from titanium alloy Ti-6%Al-4%V via AWJ technologies. In association with the TAP agreement, a best effort agreement was made to characterize fatigue specimens based on test conditions supplied by OMAX.

Hydrogen Tank Project Q2 Report - FY 11

Quarterly report that represents PNNLs results of HDPE, LDPE, and industrial polymer materials testing. ASTM D638 type 3 samples were subjected to a high pressure hydrogen environment between 3000 and 4000 PSI. These samples were tested using an instron load frame and were analyzed using a proprietary set of excel macros to determine trends in data. The development of an in-situ high pressure hydrogen tensile testing apparatus is discussed as is the stress modeling of the carbon fiber tank exterior.