Engineering topics

Lerch, Bradley A.

Publications and source records attributed to Lerch, Bradley A..

At least 19 records

NASA NTRS2019

Quasi-Static and Dynamic Analysis of Composite Panels: Characterization and Validation

The predictive capability of a progressive damage model to simulate the quasi-static and dynamic crushing of composite specimens is evaluated in this article. The material model is commercially available within the ABAQUS finite element software package, i.e., “Damage for Fiber reinforced Composites”, and is often utilized to simulate damage progression and failure in static and dynamic failure scenarios such as crushing of a composite plate. The composite specimens used in this study consist of quasi-isotropic C-shaped and corrugated composite panels comprised of carbon fiber/epoxy braided fabric. The C-shaped panel specimen is used to calibrate the model and optimize material/model properties through comparison with experimental results. Then, using the same model parameters, the quasi-static crush response of the corrugated panel is predicted. The predictive capability of the model is further demonstrated by simulating the dynamic crushing response of both C-shaped and corrugated panels using the same material properties as in the quasi-static crush case with only minor adjustments for the dynamic elastic properties (i.e., rate dependent modulus). Results show that the in-built material model available in ABAQUS can successfully reproduce experimental results for both panels (C-shaped and corrugated) subjected to both quasi-static and dynamic loading scenarios. A small-scale parametric study on physical (experimentally measurable) and nonphysical (purely mathematical) model parameters was also conducted. It can be concluded that, achieving successful simulation results requires a more in-depth understanding of the influence of model parameter variation on the mechanical response of the composite together with the strategies and challenges of the utilized modeling methodology (e.g., FEA mesh density, etc.).

Naghipour Ghezeljeh, Paria↗

NASA NTRS2019

Fatigue Behavior of Coated Titanium Alloys

Advanced multi-component TiAlCrTaSiN-based multilayered coatings were developed and processed onto Ti-6Al-4V (Ti-6-4) and GammaMet PX (GMPX or TiAl) alloys by a magnetron-enhanced physical vapor deposition technique. The coatings have recently been in development with the goal of improving advanced titanium alloy, turbine engine component durability and oxidation-erosion resistance. In this work, the performance of the multi-component coating system (including the outer layer nitride based coating and inner TiAlCrSi oxidation barrier bond coat) was studied, and the coating's influence on the fatigue behavior of the titanium-based alloys were compared. Although the multi-component coating was initially optimized to improve the coating's high temperature oxidation and erosion resistance, the lower ductility nitride-based coating needs further work on microstructure or composition to improve its mechanical stress resistance and strain tolerance for use in cyclically loaded, turbine blade operating conditions. This is particularly true for GMPX and other γ-TiAl alloys because these intermetallic titanium alloys have limited ductility and are very sensitive to defects such as coating cracks. However, the inner layer TiAlCrSi-coating had better adhesion and ductility, and may be a suitable choice to improve the oxidation resistance of titanium alloys.

Oxidation Barrier Coatings↗

NASA NTRS2019

Exploration of Failure and Potential Damage Markers in Ti-6Al-4V

To improve prognostics for predicting component life, coupon tests were conducted on Ti-6Al-4V to investigate the development of damage. Various test types were employed (tension, creep, stress relaxation, and fatigue) under a wide range of temperatures and loading rates to engage various amounts of time-dependent and damage behavior. Both stiffness degradation and Poisson’s ratio were monitored to see if they were useful in indicating the initiation and accumulation of damage and subsequently the onset of failure. Stiffness exhibited large decreases with increasing strain when calculated using engineering stress and strain. However, minimal stiffness change was observed when using the true-stress and true- strain values. Detailed microscopy and image analysis were performed to document the actual physical damage that occurred within the various specimens. Two types of damage were observed: shallow surface cracks and internal pores. The severity of damage was greater in the region of localized necking and diminished further away from the neck. The area fraction of pores was higher in the necked region, yet even there it did not exceed more than a few percent and, in most cases, was significantly lower. It was observed that conditions that induced more time-dependent deformation (e.g., slower strain rate testing) resulted in a larger number of pores and larger pore sizes. The pores were always found to occur in the softer β-phase. The severity of observed damage was inconsistent with the large drop in engineering stiffness, but was more aligned with stiffness changes from the true-stress and -strain values. Poisson’s ratio was monitored on every test and showed promise as a damage indicator. It was found to be more sensitive than either the ultimate tensile strength or the inception of tertiary creep. However, calculation of Poisson’s ratio was found to be more involved than expected because of anisotropy and the presence of strain gradients along the specimen at large applied strains. First, the material had a moderate texture and resulted in anisotropy of the strains. Second, the evolution of Poisson’s ratio as a function of axial strain showed strange and unexpected behaviors, which necessitated more extensive analyses of its development. This led to an investigation on the use of small versus large strain approaches and the importance of making consistent measurements; that is, axial and transverse strain measurements over the same volume of material. Additionally, finite element analysis of a tensile sample indicated that non- uniform strain occurred in the sample prior to attaining the maximum strength. This, along with the location at which transverse strain was measured, had a significant influence on the resulting values of Poisson’s ratio. Based on this, lessons learned are offered for future testing.

Ti-6Al-4V↗

NASA NTRS2018

Joint Strength Optimization and Damping Assessment of NiTi-Polymer Matrix Hybrid Composites

Approaches to optimize the adhesive joint strength between shape memory alloy ribbons and carbon fiber-reinforced epoxy composites were investigated for potential use as either an actuating structure or a dampening composite for structural applications. The interfacial bond strength between nickel-titanium (NiTi) and a polymer matrix composite (PMC) was measured by double lap shear testing as a function of NiTi surface treatment and adhesive material. The effect of NiTi surface treatment on damping was investigated using dynamic mechanical analysis. Lap shear data show that treating the surfaces of NiTi ribbons by light sandblasting and primer application increased the interfacial bond strength by 20 percent over the baseline composite structure. Lap shear data also reveal that out of three different film adhesives investigated, samples bonded with AF 191U and Hysol® 9696U display the highest adhesive joint strengths. Optical microscopy reveals that most samples failed by either cohesive failure within the adhesive or by adhesive failure at either the adhesive/PMC or NiTi/adhesive interface. Adhering NiTi to the PMC did not appear to negatively impact damping performance; however, a more thorough examination into NiTi's role on vibration damping should be investigated.

lap shear↗

NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗

NASA NTRS2018

Properties of 5052 Aluminum For Use as Honeycomb Core in Manned Spaceflight

This work explains that the properties of Al 5052 material used commonly for honeycomb cores in sandwich panels are highly dependent on the tempering condition. It has not been common to specify the temper when ordering HC material nor is it common for the supplier to state what the temper is. For aerospace uses, a temper of H38 or H39 is probably recommended. This temper should be stated in the bill of material and should be verified upon receipt of the core. To this end some properties provided herein can aid as benchmark values.

tensile propertie↗

NASA NTRS2017

Constitutive Modeling of the Facesheet to Core Interface in Honeycomb Sandwich Panels Subject to Mode I Delamination

A new cohesive zone traction-separation law, which includes the effects of fiber bridging, has been developed, implemented with a finite element (FE) model, and applied to simulate the delamination between the facesheet and core of a composite honeycomb sandwich panel. The proposed traction-separation law includes a standard initial cohesive component, which accounts for the initial interfacial stiffness and energy release rate, along with a new component to account for the fiber bridging contribution to the delamination process. Single cantilever beam tests on aluminum honeycomb sandwich panels with carbon fiber reinforced polymer facesheets were used to characterize and evaluate the new formulation and its finite element implementation. These tests, designed to evaluate the mode I toughness of the facesheet to core interface, exhibited significant fiber bridging and large crack process zones, giving rise to a concave downward concave upward pre-peak shape in the load-displacement curve. Unlike standard cohesive formulations, the proposed formulation captures this observed shape, and its results have been shown to be in excellent quantitative agreement with experimental load-displacement and apparent critical energy release rate results, representative of a payload fairing structure, as well as local strain fields measured with digital image correlation.

composites↗

NASA NTRS2017

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

NASA NTRS2017

Reversible and Irreversible Time-Dependent Behavior of GRCop-84

A series of mechanical tests were conducted on a high-conductivity copper alloy, GRCop-84, in order to understand the time dependent response of this material. Tensile, creep, and stress relaxation tests were performed over a wide range of temperatures, strain rates, and stress levels to excite various amounts of time-dependent behavior. At low applied stresses the deformation behavior was found to be fully reversible. Above a certain stress, termed the viscoelastic threshold, irreversible deformation was observed. At these higher stresses the deformation was observed to be viscoplastic. Both reversible and irreversible regions contained time dependent deformation. These experimental data are documented to enable characterization of constitutive models to aid in design of high temperature components.

viscoelasticity↗

NASA NTRS2016

Materials Characterization of Electron Beam Melted Ti-6Al-4V

An in-depth material characterization of Electron Beam Melted (EBM) Ti-6Al-4V material has been completed on samples fabricated on an ARCAM A2X EBM machine. The specimens were fabricated under eight separate builds with the material divided into two lots for material testing purposes. Hot Isostatic Pressing (HIP) was utilized to close porosity from fabrication and also served as a material heat treatment to obtain the desired microstructure. The changes in the microstructure and chemistry from the powder to pre-HIP and post-HIP material have been analyzed. Several nondestructive evaluation (NDE) techniques were utilized to characterize the samples both before and after HIP. The test matrix included tensile, high cycle fatigue, low cycle fatigue, fracture toughness, and fatigue crack growth at cryogenic, room, and elevated temperatures. The mechanical properties of the EBM Ti-6Al-4V are compared to conventional Ti-6Al-4V in the annealed condition. Fractography was performed to determine failure initiation site. The EBM Ti-6Al-4V had similar or superior mechanical properties compared to conventionally manufactured Ti-6Al-4V.

Titanium↗

NASA NTRS2016

Viscoplastic Characterization of Ti-6-4: Experiments

As part of a continued effort to improve the understanding of material time-dependent response, a series of mechanical tests have been conducted on the titanium alloy, Ti-6Al-4V. Tensile, creep, and stress relaxation tests were performed over a wide range of temperatures and strain rates to engage various amounts of time-dependent behavior. Additional tests were conducted that involved loading steps, overloads, dwell periods, and block loading segments to characterize the interaction between plasticity and time-dependent behavior. These data will be used to characterize a recently developed, viscoelastoplastic constitutive model with a goal toward better estimates of aerospace component behavior, resulting in improved safety.

mechanical properties↗

NASA NTRS2014

Viscoelastic Response of the Titanium Alloy Ti-6-4: Experimental Identification of Time- and Rate-Dependent Reversible and Irreversible Deformation Regions

In support of an effort on damage prognosis, the viscoelastic behavior of Ti-6Al-4V (Ti-6-4) was investigated. This report documents the experimental characterization of this titanium alloy. Various uniaxial tests were conducted to low load levels over the temperature range of 20 to 538 C to define tensile, creep, and relaxation behavior. A range of strain rates (6x10(exp -7) to 0.001/s) were used to document rate effects. All tests were designed to include an unloading portion, followed by a hold time at temperature to allow recovery to occur either at zero stress or strain. The titanium alloy was found to exhibit viscoelastic behavior below the "yield" point and over the entire range of temperatures (although at lower temperatures the magnitude is extremely small). These experimental data will be used for future characterization of a viscoelastic model.

stress relaxation↗

NASA NTRS2013

Macroscopic and Microstructural Aspects of the Transformation Behavior in a Polycrystalline NiTi Shape Memory Alloy

The mechanical and microstructural behavior of a polycrystalline Ni(49.9)Ti(50.1) (at.%) shape memory alloy was investigated as a function of temperature around the transformation regime. The bulk macroscopic responses, measured using ex situ tensile deformation and impulse excitation tests, were compared to the microstructural evolution captured using in situ neutron diffraction. The onset stress for inelastic deformation and dynamic Young's modulus were found to decrease with temperature, in the martensite regime, reaching a significant minimum at approximately 80 C followed by an increase in both properties, attributed to the martensite to austenite transformation. The initial decrease in material compliance during heating affected the ease with which martensite reorientation and detwinning could occur, ultimately impacting the stress for inelastic deformation prior to the start of the reverse transformation.

Benafan, Othmane↗

NASA NTRS2013

Impact Testing of Aluminum 2024 and Titanium 6Al-4V for Material Model Development

One of the difficulties with developing and verifying accurate impact models is that parameters such as high strain rate material properties, failure modes, static properties, and impact test measurements are often obtained from a variety of different sources using different materials, with little control over consistency among the different sources. In addition there is often a lack of quantitative measurements in impact tests to which the models can be compared. To alleviate some of these problems, a project is underway to develop a consistent set of material property, impact test data and failure analysis for a variety of aircraft materials that can be used to develop improved impact failure and deformation models. This project is jointly funded by the NASA Glenn Research Center and the FAA William J. Hughes Technical Center. Unique features of this set of data are that all material property data and impact test data are obtained using identical material, the test methods and procedures are extensively documented and all of the raw data is available. Four parallel efforts are currently underway: Measurement of material deformation and failure response over a wide range of strain rates and temperatures and failure analysis of material property specimens and impact test articles conducted by The Ohio State University; development of improved numerical modeling techniques for deformation and failure conducted by The George Washington University; impact testing of flat panels and substructures conducted by NASA Glenn Research Center. This report describes impact testing which has been done on aluminum (Al) 2024 and titanium (Ti) 6Al-4vanadium (V) sheet and plate samples of different thicknesses and with different types of projectiles, one a regular cylinder and one with a more complex geometry incorporating features representative of a jet engine fan blade. Data from this testing will be used in validating material models developed under this program. The material tests and the material models developed in this program will be published in separate reports.

Pereira, J. Michael↗

NASA NTRS2013

Experimental Identification and Simulation of Time and/or Rate Dependent Reversible and Irreversible Deformation Regions for both a Titanium and Nickel Alloy

In this paper time and/or rate dependent deformation regions are experimentally mapped out as a function of temperature. It is clearly demonstrated that the concept of a threshold stress (a stress that delineate reversible and irreversible behavior) is valid and necessary at elevated temperatures and corresponds to the classical yield stress at lower temperatures. Also the infinitely slow modulus, (Es) i.e. the elastic modulus of the material if it was loaded at an infinitely slow strain rate, and the "dynamic modulus", modulus, Ed, which represents the modulus of the material if it is loaded at an infinitely fast rate are used to delineate rate dependent from rate independent regions. As demonstrated at elevated temperatures there is a significant difference between the two modulus values, thus indicating both significant time-dependence and rate dependence. In the case of the nickel-based super alloy, ME3, this behavior is also shown to be grain size specific. Consequently, at higher temperatures viscoelastic behavior exist below k (i.e., the threshold stress) and at stresses above k the behavior is viscoplastic. Finally a multi-mechanism, stress partitioned viscoelastic model, capable of being consistently coupled to a viscoplastic model is characterized over the full temperature range investigated for Ti-6-4 and ME3.

Arnold, Steven M.↗

NASA NTRS2013

Viscoelastoplastic Deformation and Damage Response of Titanium Alloy, Ti-6Al-4V, at Elevated Temperatures

Time-dependent deformation and damage behavior can significantly affect the life of aerospace propulsion components. Consequently, one needs an accurate constitutive model that can represent both reversible and irreversible behavior under multiaxial loading conditions. This paper details the characterization and utilization of a multi-mechanism constitutive model of the GVIPS class (Generalized Viscoplastic with Potential Structure) that has been extended to describe the viscoelastoplastic deformation and damage of the titanium alloy Ti-6Al-4V. Associated material constants were characterized at five elevated temperatures where viscoelastoplastic behavior was observed, and at three elevated temperatures where damage (of both the stiffness reduction and strength reduction type) was incurred. Experimental data from a wide variety of uniaxial load cases were used to correlate and validate the proposed GVIPS model. Presented are the optimized material parameters, and the viscoelastoplastic deformation and damage responses at the various temperatures.

Arnold, Steven M.↗

NASA NTRS2012

Improvement of GRCop-84 Through the Addition of Zirconium

GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) has excellent strength, creep resistance, low cycle fatigue (LCF) life and stability at elevated temperatures. It suffers in comparison to many commercially available precipitation-strengthened alloys below 500 C (932 F). It was observed that the addition of Zr consistently improved the mechanical properties of Cu-based alloys especially below 500 C. In an effort to improve the low temperature properties of GRCop-84, 0.35 wt.% Zr was added to the alloy. Limited tensile, creep, and LCF testing was conducted to determine if improvements occur. The results showed some dramatic increases in the tensile and creep properties at the conditions tested with the probability of additional improvements being possible through cold working. LCF testing at room temperature did not show an improvement, but improvements might occur at elevated temperatures.

Ellis, David L.↗

NASA NTRS2012

Mechanical Characterization of In and Out-of-Autoclave Cured Composite Panels for Large Launch Vehicles

Two manufacturing demonstration panels (1/16th-arc-segments of 10 m diameter cylinder) were fabricated under the composites part of the Lightweight Space Structures and Materials program. Both panels were of sandwich construction with aluminum core and 8-ply quasi-isotropic graphite/epoxy facesheets. One of the panels was constructed with in-autoclave curable unidirectional prepreg (IM7/977-3) and the second with out-of-autoclave unidirectional prepreg (T40-800B/5320-1). Following NDE inspection, each panel was divided into a number of small specimens for material property characterization and a large (0.914 m wide by 1.524 m long) panel for a buckling study. Results from the small specimen tests were used to (a) assess the fabrication quality of each 1/16th arc segment panel and (b) to develop and/or verify basic material property inputs to Finite Element analysis models. The mechanical performance of the two material systems is assessed at the coupon level by comparing average measured properties such as flatwise tension, edgewise compression, and facesheet tension. The buckling response of the 0.914 m wide by 1.524 m long panel provided a comparison between the in- and out-of autoclave systems at a larger scale.

Kellas, Sotiris↗