Ultrasonic Stir Welding Development for Ground-Based and In Situ Fabrication and Repair for In-Space Propulsion Systems/Commercial Space Sector

The completed Center Innovation Fund (CIF) project used the upgraded Ultrasonic Stir Weld (USW) Prototype System (built in 2013/2014) to begin characterizing the weld process using 2219 aluminum (fig. 1). This work is being done in Bldg. 4755 at NASA Marshall Space Flight Center (MSFC). The capabilities of the USW system provides the means to precisely control and document individual welding parameters. The current upgraded system has the following capabilities: (1) Ability to 'pulse' ultrasonic (US) energy on and off and adjust parameters real-time (travel speed, spindle rpm, US amplitude, X and Z axis positions, and plunge and pin axis force; (2) Means to measure draw force; (3) Ability to record US power versus time; (4) Increasing stiffness of Z axis drive and reduce head deflection using laser technology; (5) Adding linear encoder to better control tool penetration setting; (6) Ultrasonic energy integrated into stir rod and containment plate; (7) Maximum 600 rpm; (8) Maximum Z force 15,000 lb; (9) Real-time data acquisition and logging capabilities at a minimum frequency of 10 Hz; and (10) Two separate transducer power supplies operating at 4.5 kW power

Manual adjustable probe tool for friction stir welding

A friction stir welding tool is provided generally comprising three parts: a rotatable welding tool body (22) that has an outer threaded surface (32) and a probe (24) extending from a distal end of the body, a shoulder (26), which has a threaded inner surface (40) and a bore (36) at a distal end of the shoulder, and a jam nut (28), which has a threaded inner surface (42). The shoulder is threaded onto the tool body such that the probe extends from the shoulder through the bore by a preferred length. The jam nut is then threaded onto the tool body to secure the shoulder. The tool is operatively connected to a drive motor for rotating the tool body. The shoulder may include a knife edge projecting from the distal end (38) thereof adjacent the bore. The knife edge inhibits the weld material from migrating along the probe to intrude inside the shoulder, where it may prevent separation of the tool body and the shoulder when readjustment of the tool is necessary

Advances in Solid State Joining of High Temperature Alloys

Many of the metals used in the oil and gas industry are difficult to fusion weld including titanium and its alloys. Thus solid state joining processes, such as friction stir welding (FSWing) and a patented modification termed thermal stir welding (TSWing), are being pursued as alternatives to produce robust structures more amenable to high pressure applications. Unlike the FSWing process where the tool is used to heat the workpiece, TSWing utilizes an induction coil to preheat the material prior to stirring thus minimizing the burden on the weld tool and thereby extending its life. This study reports on the initial results of using a hybrid (H)-TSW process to join commercially pure, 1.3cm thick panels of titanium (CP Ti) Grade 2

Welding Development: Marshall Space Flight Center

This paper presents the basic understanding of the friction stir welding process. It covers process description, pin tool operation and materials, metal flow theory, mechanical properties, and materials welded using the process. It also discusses the thermal stir welding process and the differences between thermal stir and friction stir welding. MSFC weld tools used for development are also presented

Chemical and device degradation in PCPDTBT: PCBM solar cells using XPS and ToF-SIMS

Analysis of the degradation routes for PCPDTBT-based solar cells under illumination and in the presence of air have been conducted using a combination of X-ray Photoelectron Spectroscopy (XPS), Time-Of-Flight Secondary Ion Mass Spectrometry (TOF-SIMS) and solar cell device data. After ageing, XPS studies show that PCPDTBT appears as an oxygen-containing polymer, with data indicating that a break-up in the aromatic rings, formation of sulphates at the thiophene ring, chain scission in the polymer backbone and also loss of side chains. XPS studies on active layers blends of PCPDTBT and PCBM also show significant changes in the vertical composition during ageing, with increased enrichment of PCPDTBT observed at the top surface and that the use of a processing additive (ODT) has a negative impact on the morphological stability. TOF-SIMS has been used to study electrode degradation during ageing experiments leads to migration of indium and tin ions into the active layer in non-inverted devices, but is eliminated for inverted devices.RAEng and EC financial support and Prof TJ Lewis (Bangor) for technical suppor

NASA'S MSFC Welding Development for Ares I

This slide presentation reviews the development of welding for the Ares I launch vehicle. Shown are views of the Ares I and Ares 5, and comparisons with the space shuttle and Saturn V launch vehicles. The elements, and the contractor charged with developing each is shown. The various types of welding capabilities are reviewed. Pictures of the various welding systems available at Marshall Space Flight Center are shown

Characterization of the Ultrasonic Stir Welding (USW) Process

No abstract availabl

Targeted online password guessing:an underestimated threat

While trawling online/offline password guessing has been intensively studied, only a few studies have examined targeted online guessing, where an attacker guesses a specific victim's password for a service, by exploiting the victim's personal information such as one sister password leaked from her another account and some personally identifiable information (PII). A key challenge for targeted online guessing is to choose the most effective password candidates, while the number of guess attempts allowed by a server's lockout or throttling mechanisms is typically very small. We propose TarGuess, a framework that systematically characterizes typical targeted guessing scenarios with seven sound mathematical models, each of which is based on varied kinds of data available to an attacker. These models allow us to design novel and efficient guessing algorithms. Extensive experiments on 10 large real-world password datasets show the effectiveness of TarGuess. Particularly, TarGuess I~IV capture the four most representative scenarios and within 100 guesses: (1) TarGuess-I outperforms its foremost counterpart by 142% against security-savvy users and by 46% against normal users; (2) TarGuess-II outperforms its foremost counterpart by 169% on security-savvy users and by 72% against normal users; and (3) Both TarGuess-III and IV gain success rates over 73% against normal users and over 32% against security-savvy users. TarGuess-III and IV, for the first time, address the issue of cross-site online guessing when given the victim's one sister password and some PII