A method, apparatus and system for testing characteristics of a material sample is provided. The system includes an apparatus configured to house the material test sample while defining a sealed volume against a surface of the material test sample. A source of pressurized fluid is in communication with, and configured to pressurize, the sealed volume. A load applying apparatus is configured to apply a defined load to the material sample while the sealed volume is monitored for leakage of the pressurized fluid. Thus, the inducement of surface defects such as microcracking and crazing may be detected and their effects analyzed for a given material. The material test samples may include laminar structures formed of, for example, carbon cloth phenolic, glass cloth phenolic, silica cloth phenolic materials or carbon-carbon materials. In one embodiment the system may be configured to analyze the material test sample while an across-ply loading is applied thereto.

Johnson, David L.↗

NASA NTRS2005

Method for Estimating Thread Strength Reduction of Damaged Parent Holes with Inserts

During normal assembly and disassembly of bolted-joint components, thread damage and/or deformation may occur. If threads are overloaded, thread damage/deformation can also be anticipated. Typical inspection techniques (e.g. using GO-NO GO gages) may not provide adequate visibility of the extent of thread damage. More detailed inspection techniques have provided actual pitch-diameter profiles of damaged-hardware holes. A method to predict the reduction in thread shear-out capacity of damaged threaded holes has been developed. This method was based on testing and analytical modeling. Test samples were machined to simulate damaged holes in the hardware of interest. Test samples containing pristine parent-holes were also manufactured from the same bar-stock material to provide baseline results for comparison purposes. After the particular parent-hole thread profile was machined into each sample a helical insert was installed into the threaded hole. These samples were tested in a specially designed fixture to determine the maximum load required to shear out the parent threads. It was determined from the pristine-hole samples that, for the specific material tested, each individual thread could resist an average load of 3980 pounds. The shear-out loads of the holes having modified pitch diameters were compared to the ultimate loads of the specimens with pristine holes. An equivalent number of missing helical coil threads was then determined based on the ratio of shear-out loads for each thread configuration. These data were compared with the results from a finite element model (FEM). The model gave insights into the ability of the thread loads to redistribute for both pristine and simulated damage configurations. In this case, it was determined that the overall potential reduction in thread load-carrying capability in the hardware of interest was equal to having up to three fewer threads in the hole that bolt threads could engage. One- half of this potential reduction was due to local pitch-diameter variations and the other half was due to overall pitch-diameter enlargement beyond Class 2 fit. This result was important in that the thread shear capacity for this particular hardware design was the limiting structural capability. The details of the method development, including the supporting testing, data reduction and analytical model results comparison will be discussed hereafter.

Johnson, David L.↗

NASA NTRS1992

Improvements to the missile aerodynamic prediction code DEMON3

The computer program DEMON3 was developed for the aerodynamic analysis of nonconventional supersonic configurations comprising a body with noncircular cross section and up to two wing or fin sections. Within a wing or fin section, the lifting surfaces may be cruciform, triform, planar, or low profile layouts; the planforms of the lifting surfaces allow for breaks in sweep. The body and fin sections are modeled by triplet and constant u-velocity panels, respectively, accounting for mutual body-fin interference. Fin thickness effects are included for the use of supersonic planar source panels. One of the unique features of DEMON3 is the modeling of high angle of attack vortical effects associated with the lifting surfaces and the body. In addition, shock expansion and Newtonian pressure calculation methods can be optionally engaged. These two dimensional nonlinear methods are augmented by aerodynamic interference determined from the linear panel methods. Depending on the geometric details of the body, the DEMON3 program can be used to analyze nonconventional configurations at angles of attack up to 25 degrees for Mach numbers from 1.1 to 6. Calculative results and comparisons with experimental data demonstrate the capabilities of DEMON3. Limitations and deficiencies are listed.

Dillenius, Marnix F. E.↗