John C. McClure

Bio: John C. McClure is an academic researcher from University of Texas at El Paso. The author has contributed to research in topics: Welding & Friction stir welding. The author has an hindex of 28, co-authored 74 publications receiving 4220 citations. Previous affiliations of John C. McClure include University of Texas at Austin & National Autonomous University of Mexico.

Flow Patterns During Friction Stir Welding

Abstract: 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.

Flow visualization and residual microstructures associated with the friction-stir welding of 2024 aluminum to 6061 aluminum

Abstract: The friction-stir welding (FSW) of 0.6 cm plates of 2024 Al (140 HV) to 6061 Al (100 HV) is characterized by residual, equiaxed grains within the weld zone having average sizes ranging from 1 to 15 μm, exhibiting grain growth from dynamically recrystallized grains which provide a mechanism for superplastic flow; producing intercalated, lamellar-like flow patterns. These flow patterns are visualized by differential etching of the 2024 Al producing contrast relative to 6061 Al. The flow patterns are observed to be complex spirals and vortex-like, among others, and to change somewhat systematically with tool rotation (stirring) speed between 400 and 1200 rpm; depending on tool orientation. The equiaxed grain and sub-grain microstructures are observed to vary according to estimated temperature profiles (varying from 0.6 to 0.8 TM, where TM is the absolute melting temperature) referenced to the rotating tool axis. Dislocation spirals and loops are also observed in the 2024 Al intercalation regions within the weld zones at higher speeds (>800 rpm) corresponding to slightly elevated temperatures introducing dislocation climb, and residual microhardness profiles follow microstructural variations which result in a 40% reduction in the 6061 Al workpiece microhardness and a 50% reduction in the 2024 Al workpiece microhardness just outside the FSW zone.

Friction Stir Welding and Processing

Abstract: Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a decade. Recently, friction stir processing (FSP) was developed for microstructural modification of metallic materials. In this review article, the current state of understanding and development of the FSW and FSP are addressed. Particular emphasis has been given to: (a) mechanisms responsible for the formation of welds and microstructural refinement, and (b) effects of FSW/FSP parameters on resultant microstructure and final mechanical properties. While the bulk of the information is related to aluminum alloys, important results are now available for other metals and alloys. At this stage, the technology diffusion has significantly outpaced the fundamental understanding of microstructural evolution and microstructure–property relationships.

Exploration of the active center structure of nitrogen-doped graphene-based catalysts for oxygen reduction reaction

Abstract: We present two different ways to fabricate nitrogen-doped graphene (N-graphene) and demonstrate its use as a metal-free catalyst to study the catalytic active center for the oxygen reduction reaction (ORR). N-graphene was produced by annealing of graphene oxide (G-O) under ammonia or by annealing of a N-containing polymer/reduced graphene oxide (RG-O) composite (polyaniline/RG-O or polypyrrole/RG-O). The effects of the N precursors and annealing temperature on the performance of the catalyst were investigated. The bonding state of the N atom was found to have a significant effect on the selectivity and catalytic activity for ORR. Annealing of G-O with ammonia preferentially formed graphitic N and pyridinic N centers, while annealing of polyaniline/RG-O and polypyrrole/RG-O tended to generate pyridinic and pyrrolic N moieties, respectively. Most importantly, the electrocatalytic activity of the catalyst was found to be dependent on the graphitic N content which determined the limiting current density, while the pyridinic N content improved the onset potential for ORR. However, the total N content in the graphene-based non-precious metal catalyst does not play an important role in the ORR process.

Thin-film solar cells: an overview

Abstract: Thin film solar cells (TFSC) are a promising approach for terrestrial and space photovoltaics and offer a wide variety of choices in terms of the device design and fabrication. A variety of substrates (flexible or rigid, metal or insulator) can be used for deposition of different layers (contact, buffer, absorber, reflector, etc.) using different techniques (PVD, CVD, ECD, plasma-based, hybrid, etc.). Such versatility allows tailoring and engineering of the layers in order to improve device performance. For large-area devices required for realistic applications, thin-film device fabrication becomes complex and requires proper control over the entire process sequence. Proper understanding of thin-film deposition processes can help in achieving high-efficiency devices over large areas, as has been demonstrated commercially for different cells. Research and development in new, exotic and simple materials and devices, and innovative, but simple manufacturing processes need to be pursued in a focussed manner. Which cell(s) and which technologies will ultimately succeed commercially continue to be anybody's guess, but it would surely be determined by the simplicity of manufacturability and the cost per reliable watt. Cheap and moderately efficient TFSC are expected to receive a due commercial place under the sun.