Engineering topics

Bonacuse, Peter J.

Publications and source records attributed to Bonacuse, Peter J..

At least 19 records

NASA NTRS2014

NDE Software Developed at NASA Glenn Research Center

NASA Glenn Research Center has developed several important Nondestructive Evaluation (NDE) related software packages for different projects in the last 10 years. Three of the software packages have been created with commercial-grade user interfaces and are available to United States entities for download on the NASA Technology Transfer and Partnership Office server (https://sr.grc.nasa.gov/). This article provides brief overviews of the software packages.

image processing↗

NASA NTRS2012

Modeling of Damage Initiation and Progression in a SiC/SiC Woven Ceramic Matrix Composite

The goal of an ongoing project at NASA Glenn is to investigate the effects of the complex microstructure of a woven ceramic matrix composite and its variability on the effective properties and the durability of the material. Detailed analysis of these complex microstructures may provide clues for the material scientists who `design the material? or to structural analysts and designers who `design with the material? regarding damage initiation and damage propagation. A model material system, specifically a five-harness satin weave architecture CVI SiC/SiC composite composed of Sylramic-iBN fibers and a SiC matrix, has been analyzed. Specimens of the material were serially sectioned and polished to capture the detailed images of fiber tows, matrix and porosity. Open source analysis tools were used to isolate various constituents and finite elements models were then generated from simplified models of those images. Detailed finite element analyses were performed that examine how the variability in the local microstructure affected the macroscopic behavior as well as the local damage initiation and progression. Results indicate that the locations where damage initiated and propagated is linked to specific microstructural features.

Mital, Subodh K.↗

NASA NTRS2012

Investigation of Effects of Material Architecture on the Elastic Response of a Woven Ceramic Matrix Composite

To develop methods for quantifying the effects of the microstructural variations of woven ceramic matrix composites on the effective properties and response of the material, a research program has been undertaken which is described in this paper. In order to characterize and quantify the variations in the microstructure of a five harness satin weave, CVI SiC/SiC, composite material, specimens were serially sectioned and polished to capture images that detailed the fiber tows, matrix, and porosity. Open source quantitative image analysis tools were then used to isolate the constituents and collect relevant statistics such as within ply tow spacing. This information was then used to build two dimensional finite element models that approximated the observed section geometry. With the aid of geometrical models generated by the microstructural characterization process, finite element models were generated and analyses were performed to quantify the effects of the microstructure and its variation on the effective stiffness and areas of stress concentration of the material. The results indicated that the geometry and distribution of the porosity appear to have significant effects on the through-thickness modulus. Similarly, stress concentrations on the outer surface of the composite appear to correlate to regions where the transverse tows are separated by a critical amount.

Goldberg, Robert K.↗

NASA NTRS2012

Two-Dimensional Nonlinear Finite Element Analysis of CMC Microstructures

A research program has been developed to quantify the effects of the microstructure of a woven ceramic matrix composite and its variability on the effective properties and response of the material. In order to characterize and quantify the variations in the microstructure of a five harness satin weave, chemical vapor infiltrated (CVI) SiC/SiC composite material, specimens were serially sectioned and polished to capture images that detailed the fiber tows, matrix, and porosity. Open source quantitative image analysis tools were then used to isolate the constituents, from which two dimensional finite element models were generated which approximated the actual specimen section geometry. A simplified elastic-plastic model, wherein all stress above yield is redistributed to lower stress regions, is used to approximate the progressive damage behavior for each of the composite constituents. Finite element analyses under in-plane tensile loading were performed to examine how the variability in the local microstructure affected the macroscopic stress-strain response of the material as well as the local initiation and progression of damage. The macroscopic stress-strain response appeared to be minimally affected by the variation in local microstructure, but the locations where damage initiated and propagated appeared to be linked to specific aspects of the local microstructure.

Mital, Subodh K.↗

NASA NTRS2011

Characterization of the as Manufactured Variability in a CVI SiC/SiC Woven Composite

The microstructure of a 2D woven ceramic matrix composite displays significant variability and irregularity. For example, a chemical vapor infiltrated (CVI) SiC/SiC composite exhibits significant amount of porosity arranged in irregular patterns. Furthermore, the fiber tows within a ply frequently have irregular shape and spacing, and the stacked plies are often misaligned and irregularly nested within each other. The goal of an ongoing project at NASA Glenn is to investigate the effects of the complex microstructure and its variability on the properties and the durability of the material. One key requirement for this effort is the development of methods to characterize the distribution in as-fabricated ceramic matrix composite (CMC) microstructures with the objective of correlating microstructural distribution parameters with mechanical performance. An initial task in this effort was to perform quantitative image analysis of polished cross sections of CVI SiC/SiC composite specimens. This analysis provided sample distributions of various microstructural composite features, including: inter-tow pore sizes and shapes, transverse sectioned tow sizes and shapes, and within ply tow spacing. This information can then be used to quantify the effect of extreme values of these features on the local stress state with the goal of determining the likelihood of matrix cracking at a given external load.

Bonacuse, Peter J.↗

NASA NTRS2011

Two-Dimensional Nonlinear Finite Element Analysis of CMC Microstructures

Detailed two-dimensional finite element analyses of the cross-sections of a model CVI (chemical vapor infiltrated) SiC/SiC (silicon carbide fiber in a silicon carbide matrix) ceramic matrix composites are performed. High resolution images of the cross-section of this composite material are generated using serial sectioning of the test specimens. These images are then used to develop very detailed finite element models of the cross-sections using the public domain software OOF2 (Object Oriented Analysis of Material Microstructures). Examination of these images shows that these microstructures have significant variability and irregularity. How these variabilities manifest themselves in the variability in effective properties as well as the stress distribution, damage initiation and damage progression is the overall objective of this work. Results indicate that even though the macroscopic stress-strain behavior of various sections analyzed is very similar, each section has a very distinct damage pattern when subjected to in-plane tensile loads and this damage pattern seems to follow the unique architectural and microstructural details of the analyzed sections.

Mital, Subodh K.↗

NASA NTRS2010

An Assessment of Cumulative Axial and Torsional Fatigue in a Cobalt-Base Superalloy

Cumulative fatigue under axial and torsional loading conditions can include both load-order (higMow and low/high) as well as load-type sequence (axial/torsional and torsional/axial) effects. Previously reported experimental studies on a cobalt-base superalloy, Haynes 188 at 538 C, addressed these effects. These studies characterized the cumulative axial and torsional fatigue behavior under high amplitude followed by low amplitude (Kalluri, S. and Bonacuse, P. J., "Cumulative Axial and Torsional Fatigue: An Investigation of Load-Type Sequance Effects," in Multiaxial Fatigue and Deformation: Testing and Prediction, ASTM STP 1387, S. Kalluri, and P. J. Bonacuse, Eds., American Society for Testing and Materials, West Conshohocken, PA, 2000, pp. 281-301) and low amplitude followed by high amplitude (Bonacuse, P. and Kalluri, S. "Sequenced Axial and Torsional Cumulative Fatigue: Low Amplitude Followed by High Amplitude Loading," Biaxial/Multiaxial Fatigue and Fracture, ESIS Publication 31, A. Carpinteri, M. De Freitas, and A. Spagnoli, Eds., Elsevier, New York, 2003, pp. 165-182) conditions. In both studies, experiments with the following four load-type sequences were performed: (a) axial/axial, (b) torsional/torsional, (c) axial/torsional, and (d) torsional/axial. In this paper, the cumulative axial and torsional fatigue data generated in the two previous studies are combined to generate a comprehensive cumulative fatigue database on both the load-order and load-type sequence effects. This comprehensive database is used to examine applicability of the Palmgren-langer-Miner linear damage rule and a nonlinear damage curve approach for Haynes 188 subjected to the load-order and load-type sequencing described above. Summations of life fractions from the experiments are compared to the predictions from both the linear and nonlinear cumulative fatigue damage approaches. The significance of load-order versus load-type sequence effects for axial and torsional loading conditions is discussed. Possible reasons for the observed differences between the computed and observed summations of cycle fractions are rationalized in terms of the observed ever lutions of cyclic axial and shear stress ranges in the cumulative fatigue tests.

Kalluri, Sreeramesh↗

NASA NTRS2008

Geometric Modeling of Inclusions as Ellipsoids

Nonmetallic inclusions in gas turbine disk alloys can have a significant detrimental impact on fatigue life. Because large inclusions that lead to anomalously low lives occur infrequently, probabilistic approaches can be utilized to avoid the excessively conservative assumption of lifing to a large inclusion in a high stress location. A prerequisite to modeling the impact of inclusions on the fatigue life distribution is a characterization of the inclusion occurrence rate and size distribution. To help facilitate this process, a geometric simulation of the inclusions was devised. To make the simulation problem tractable, the irregularly sized and shaped inclusions were modeled as arbitrarily oriented, three independent dimensioned, ellipsoids. Random orientation of the ellipsoid is accomplished through a series of three orthogonal rotations of axes. In this report, a set of mathematical models for the following parameters are described: the intercepted area of a randomly sectioned ellipsoid, the dimensions and orientation of the intercepted ellipse, the area of a randomly oriented sectioned ellipse, the depth and width of a randomly oriented sectioned ellipse, and the projected area of a randomly oriented ellipsoid. These parameters are necessary to determine an inclusion s potential to develop a propagating fatigue crack. Without these mathematical models, computationally expensive search algorithms would be required to compute these parameters.

Bonacuse, Peter J.↗

NASA NTRS2007

Best Practices for Reliable and Robust Spacecraft Structures

A study was undertaken to capture the best practices for the development of reliable and robust spacecraft structures for NASA s next generation cargo and crewed launch vehicles. In this study, the NASA heritage programs such as Mercury, Gemini, Apollo, and the Space Shuttle program were examined. A series of lessons learned during the NASA and DoD heritage programs are captured. The processes that "make the right structural system" are examined along with the processes to "make the structural system right". The impact of technology advancements in materials and analysis and testing methods on reliability and robustness of spacecraft structures is studied. The best practices and lessons learned are extracted from these studies. Since the first human space flight, the best practices for reliable and robust spacecraft structures appear to be well established, understood, and articulated by each generation of designers and engineers. However, these best practices apparently have not always been followed. When the best practices are ignored or short cuts are taken, risks accumulate, and reliability suffers. Thus program managers need to be vigilant of circumstances and situations that tend to violate best practices. Adherence to the best practices may help develop spacecraft systems with high reliability and robustness against certain anomalies and unforeseen events.

Raju, Ivatury S.↗

NASA NTRS2005

Orbiter LH2 Feedline Flowliner Cracking Problem

In May of 2002, three cracks were found in the downstream flowliner at the gimbal joint in the LH2 feedline at the interface with the Low Pressure Fuel Turbopump (LPFP) of Space Shuttle Main Engine (SSME) #1 of Orbiter OV-104. Subsequent inspections of the feedline flowliners in the other orbiters revealed the existence of 8 additional cracks. No cracks were found in the LO2 feedline flowliners. A solution to the cracking problem was developed and implemented on all orbiters. The solution included weld repair of all detectable cracks and the polishing of all slot edges to remove manufacturing discrepancies that could initiate new cracks. Using the results of a fracture mechanics analysis with a scatter factor of 4 on the predicted fatigue life, the orbiters were cleared for return to flight with a one-flight rationale requiring inspections after each flight. OV-104 flew mission STS-112 and OV-105 flew mission STS-113. The post-flight inspections did not find any cracks in the repaired flowliners. At the request of the Orbiter Program, the NESC conducted an assessment of the Orbiter LH2 Feedline Flowliner cracking problem with a team of subject matter experts from throughout NASA.

Harris, Charles E.↗

NASA NTRS2005

Probabilistic Fracture Mechanics Analysis of the Orbiter's LH2 Feedline Flowliner

Work performed by Southwest Research Institute (SwRI) as part of an Independent Technical Assessment (ITA) for the NASA Engineering and Safety Center (NESC) is summarized. The ITA goal was to establish a flight rationale in light of a history of fatigue cracking due to flow induced vibrations in the feedline flowliners that supply liquid hydrogen to the space shuttle main engines. Prior deterministic analyses using worst-case assumptions predicted failure in a single flight. The current work formulated statistical models for dynamic loading and cryogenic fatigue crack growth properties, instead of using worst-case assumptions. Weight function solutions for bivariant stressing were developed to determine accurate crack "driving-forces". Monte Carlo simulations showed that low flowliner probabilities of failure (POF = 0.001 to 0.0001) are achievable, provided pre-flight inspections for cracks are performed with adequate probability of detection (POD)-specifically, 20/75 mils with 50%/99% POD. Measurements to confirm assumed POD curves are recommended. Since the computed POFs are very sensitive to the cyclic loads/stresses and the analysis of strain gage data revealed inconsistencies with the previous assumption of a single dominant vibrant mode, further work to reconcile this difference is recommended. It is possible that the unaccounted vibrational modes in the flight spectra could increase the computed POFs.

Bonacuse, Peter J.↗

NASA NTRS2005

Effectiveness of Shot Peening in Suppressing Fatigue Cracking at Non-Metallic Inclusions in Udimet(trademark) 720

The fatigue lives of modern powder metallurgy disk alloys can be reduced by over an order of magnitude by surface cracking at inherent non-metallic inclusions. The objective of this work was to study the effectiveness of shot peening in suppressing LCF crack initiation and growth at surface nonmetallic inclusions. Inclusions were carefully introduced at elevated levels during powder metallurgy processing of the nickel-base disk superalloy Udimet 720. Multiple strain-controlled fatigue tests were then performed on machined specimens at 427 and 650 C in peened and unpeened conditions. Analyses were performed to compare the low cycle fatigue lives and failure initiation sites as a function of inclusion content, shot peening, and fatigue conditions. A large majority of the failures in as-machined specimens with introduced inclusions occurred at cracks initiating from inclusions intersecting the specimen surface. The inclusions could reduce fatigue life by up to 100X. Large inclusions had the greatest effect on life in tests at low strain ranges and high strain ratios. Shot peening can be used to improve life in these conditions by reducing the most severe effects of inclusions.

Barrie, Robert L.↗

NASA NTRS2004

Distribution of Inclusion-Initiated Fatigue Cracking in Powder Metallurgy Udimet 720 Characterized

In the absence of extrinsic surface damage, the fatigue life of metals is often dictated by the distribution of intrinsic defects. In powder metallurgy (PM) alloys, relatively large defects occur rarely enough that a typical characterization with a limited number of small volume fatigue test specimens will not adequately sample inclusion-initiated damage. Counterintuitively, inclusion-initiated failure has a greater impact on the distribution in PM alloy fatigue lives because they tend to have fewer defects than their cast and wrought counterparts. Although the relative paucity of defects in PM alloys leads to higher mean fatigue lives, the distribution in observed lives tends to be broader. In order to study this important failure initiation mechanism without expending an inordinate number of specimens, a study was undertaken at the NASA Glenn Research Center where known populations of artificial inclusions (seeds) were introduced to production powder. Fatigue specimens were machined from forgings produced from the seeded powder. Considerable effort has been expended in characterizing the crack growth rate from inclusion-initiated cracks in seeded PM alloys. A rotating and translating positioning system, with associated software, was devised to map the surface inclusions in low-cycle fatigue (LCF) test bars and to monitor the crack growth from these inclusions. The preceding graph illustrates the measured extension in fatigue cracks from inclusions on a seeded LCF test bar subjected to cyclic loading at a strain range of 0.8 percent and a strain ratio (max/min) of zero. Notice that the observed inclusions fall into three categories: some do not propagate at all (arrest), some propagate with a decreasing crack growth rate, and a few propagate at increasing rates that can be modeled by fracture mechanics. The following graph shows the measured inclusion-initiated crack growth rates from 10 interrupted LCF tests plotted against stress intensities calculated for semi-elliptical cracks with the observed surface lengths. The expected scatter in the crack growth rates for stress intensity ranges near threshold is observed. These data will be used to help determine the distribution in growth rates of cracks emanating from inclusions as well as the proportion of cracks that arrest under various loading conditions.

Bonacuse, Peter J.↗

NASA NTRS2002

Major Effects of Nonmetallic Inclusions on the Fatigue Life of Disk Superalloy Demonstrated

The fatigue properties of modern powder metallurgy disk alloys can vary because of the different steps of materials and component processing and machining. Among these variables, the effects of nonmetallic inclusions introduced during the powder atomization and handling processes have been shown to significantly degrade low-cycle fatigue life. The levels of inclusion contamination have, therefore, been reduced to less than 1 part per million in state-of-the-art nickel disk powder-processing facilities. Yet the large quantities of compressor and turbine disks weighing from 100 to over 1000 lb have enough total volume and surface area for these rare inclusions to still be present and limit fatigue life. The objective of this study was to investigate the effects on fatigue life of these inclusions, as part of the Crack Resistant Disk Materials task within the Ultra Safe Propulsion Project. Inclusions were carefully introduced at elevated levels in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were then performed on extracted test specimens at 650 C. Analyses were performed to compare the low-cycle fatigue lives and failure initiation sites as functions of inclusion content and fatigue conditions. Powder of the nickel-base superalloy U720 was atomized in argon at Special Metals Corporation, Inc., using production-scale high-cleanliness powder-processing facilities and handling practices. The powder was then passed through a 270-mesh screen. One portion of this powder was set aside for subsequent consolidation without introduced inclusions. Two other portions of this powder were seeded with alumina inclusions. Small, polycrystalline soft (Type 2) inclusions of about 50 mm diameter were carefully prepared and blended into one powder lot, and larger hard (Type 1) inclusions of about 150 mm mean diameter were introduced into the other seeded portion of powder. All three portions of powder were then sealed in separate containers, hot isostatically pressurized, extruded, forged into subscale disks, and heat treated. Low-cycle-fatigue specimens were then extracted, machined, and tested. Fatigue tests were performed at 650 C in closed-loop servohydraulic testing machines using induction heating and axial extensometers. All tests were continued to failure, and fractographic evaluations were performed on all specimens to determine the crack initiation sites. A large majority of the failures in specimens with introduced inclusions occurred at cracks initiating from inclusions at the specimen surface, as shown for each type of inclusion in the following bar chart. The inclusions significantly reduced fatigue life from unseeded material levels, as shown in the bar chart. These effects were found to depend on the strain range, strain ratio, and inclusion size. Tests at lower strain ranges and higher strain ratios resulted in larger effects of inclusions on life. Inclusion effects on life were thereby maximized in tests at the lowest strain range of 0.6 percent and the most positive strain ratio of 0.5. Under these conditions, small Type 2 inclusions reduced life substantially-- about 20 times, whereas large Type 1 inclusions dramatically reduced life 100 times. These results clearly demonstrate that it is essential to include the effects of inclusions for realistic predictions of disk fatigue life. Important issues, including temperature dependence, crack initiation versus propagation, surface treatments, realistic disk features and machining, and realistic disk spin testing will be addressed to accurately model inclusion effects on disk fatigue life. Fatigue life varied from well over 105 cycles for no inclusions to a little over 103 cycles for 100-micrometer inclusions. A single crack initiating at a surface-connected seeded inclusion caused failure in each case.

Gabb, Timothy P.↗

NASA NTRS2002

Scanning Electron Microscope Mapping System Developed for Detecting Surface Defects in Fatigue Specimens

An automated two-degree-of-freedom specimen positioning stage has been developed at the NASA Glenn Research Center to map and monitor defects in fatigue specimens. This system expedites the examination of the entire gauge section of fatigue specimens so that defects can be found using scanning electron microscopy (SEM). Translation and rotation stages are driven by microprocessor-based controllers that are, in turn, interfaced to a computer running custom-designed software. This system is currently being used to find and record the location of ceramic inclusions in powder metallurgy materials. The mapped inclusions are periodically examined during interrupted fatigue experiments. The number of cycles to initiate cracks from these inclusions and the rate of growth of initiated cracks can then be quantified. This information is necessary to quantify the effect of this type of defect on the durability of powder metallurgy materials. This system was developed with support of the Ultra Safe program.

Bonacuse, Peter J.↗

NASA NTRS2001

Ceramic Inclusions in Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially in turbine disk applications. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that are inherent to the powder atomization process. These inclusions can have a potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they typically do not reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where known populations of ceramic particles, whose composition and morphology are designed to mimic the "natural" inclusions, are added to the precursor powder. Surface-connected inclusions have been found to have a particularly large detrimental effect on fatigue life; therefore, the quantity of ceramic "seeds" added is calculated to ensure that a minimum number will intersect the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface area was needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macroscopic slices from extrusions and forgings. Fatigue specimens have been machined from Udimet 720 (a powder metallurgy superalloy) forgings, to determine the effects of the inclusions on fatigue life. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions. This work has been supported by the Ultra Safe and Ultra- Efficient Engine Technologies programs.

Bonacuse, Peter J.↗

NASA NTRS2001

Axial and Torsional Load-Type Sequencing in Cumulative Fatigue: Low Amplitude Followed by High Amplitude Loading

The experiments described herein were performed to determine whether damage imposed by axial loading interacts with damage imposed by torsional loading. This paper is a follow on to a study that investigated effects of load-type sequencing on the cumulative fatigue behavior of a cobalt base superalloy, Haynes 188 at 538 C Both the current and the previous study were used to test the applicability of cumulative fatigue damage models to conditions where damage is imposed by different loading modes. In the previous study, axial and torsional two load level cumulative fatigue experiments were conducted, in varied combinations, with the low-cycle fatigue (high amplitude loading) applied first. In present study, the high-cycle fatigue (low amplitude loading) is applied initially. As in the previous study, four sequences (axial/axial, torsion/torsion, axial/torsion, and torsion/axial) of two load level cumulative fatigue experiments were performed. The amount of fatigue damage contributed by each of the imposed loads was estimated by both the Palmgren-Miner linear damage rule (LDR) and the non-linear damage curve approach (DCA). Life predictions for the various cumulative loading combinations are compared with experimental results.

Bonacuse, Peter J.↗

NASA NTRS2000

Assessment of Low Cycle Fatigue Behavior of Powder Metallurgy Alloy U720

The fatigue lives of modem powder metallurgy disk alloys are influenced by variabilities in alloy microstructure and mechanical properties. These properties can vary as functions of variables the different steps of materials/component processing: powder atomization, consolidation, extrusion, forging, heat treating, and machining. It is important to understand the relationship between the statistical variations in life and these variables, as well as the change in life distribution due to changes in fatigue loading conditions. The objective of this study was to investigate these relationships in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were performed at 538 C (1000 F) at limited sets of test conditions. Analyses were performed to: (1) assess variations of microstructure, mechanical properties, and LCF failure initiation sites as functions of disk processing and loading conditions; and (2) compare mean and minimum fatigue life predictions using different approaches for modeling the data from assorted test conditions. Significant variations in life were observed as functions of the disk processing variables evaluated. However, the lives of all specimens could still be combined and modeled together. The failure initiation sites for tests performed at a strain ratio R(sub epsilon) = epsilon(sub min)/epsilon(sub max) of 0 were different from those in tests at a strain ratio of -1. An approach could still be applied to account for the differences in mean and maximum stresses and strains. This allowed the data in tests of various conditions to be combined for more robust statistical estimates of mean and minimum lives.

Gabb, Tomothy P.↗