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NASA NTRS1984

Fracture temperature and flaw growth in nitronic 40 at cryogenic temperatures

The fracture resistance and fatigue response of Armco Nitronic 40 austenitic stainless steel were evaluated under cryogenic conditions. Tensile, fracture toughness and fatigue crack growth properties were measured at -275 F. The tensile yield strength was approximately 120 ksi and the fracture toughness was estimated to be 350 ksi-in /2 on the basis of fracture toughness measurements. Testing was conducted to evaluate the behavior of a simulated section of the wing of the Pathfinder 1 model subject to a load and temperature history typical of that for testing in the National Transonic Facility. The wing section model incorporated a proposed brazing technique for pressure-transducer attachment. The simulated wing section performed satisfactorily at stress levels of nearly 60 percent of the material yield strength. The brazing technique proved to be an effective method of transducer attachment under conditions of high stress levels and large temperature excursions.

Domack, M. S.↗

NASA NTRS1983

The effects of laminate thickness on the fracture behavior of composite laminates

The relationship between both fracture toughness and the development of crack-tip damage as a function of specimen thickness was investigated. Fracture toughness was determined experimentally using center-cracked tension specimens for (0/plus or minus 45/90)ns and (0/90)ns laminates, where ns means multiple layers with the same repeated sequence and symmetric about the midplane. Laminate thicknesses ranged from 8 plies to 96 plies. As with isotropic metals, fracture toughness was found to decrease with increasing specimen thickness and asymptotically approached a lower bound. The crack tip damage in the (0/plus or minus 45/90)ns laminate does not appear to be a function of thickness. However, there are differences in the damage of the (0/90)2s and (0/90)8s laminates and associated differences in fracture toughness.

Harris, C. E.↗

NASA NTRS1983

Compositional effects on Si3N4 fracture surfaces

Surface analysis techniques (X-ray, infrared reflection spectroscopy, Auger electron spectroscopy) applied to the same samples reveal that fracture surfaces of Si3N4 with Y2O3 densification aids possess a higher concentration of oxygen than the bulk. The oxide densification aids thus concentrate in the grain boundaries, and even low-temperature fracture is seen as occurring preferentially within the oxygen-enriched grain boundaries. It is found that increasing the concentrations of Y2O3 and Al2O3 increases the oxygen content of the fracture surface. A range of 13-15 percent Y2O3 + 6 percent Al2O3 gives an amorphous grain-boundary phase that is resistant to devitrification. Fracture occurs through the amorphous phase, and heat treatment at 1000 C has little effect on the amorphous phase.

Hench, L. L.↗

NASA NTRS1984

Off-axis tensile properties and fracture in a unidirectional graphite/polyimide composite (Celion 6000/PMR 15)

Tensile properties of unidirectional Celion 6000 graphite/PMR 15 polyimide composites prepared by hot molding and cold molding processes were measured at room temperature and 316 C, the upper use temperature of the polyimide resin, at both 45 and 90 deg to the fiber axis. The resulting fractures were characterized by scanning electron microscopy and materialographic techniques. Variation in tensile properties with processing history occurred in the elastic modulus and strain to failure for specimens loaded at 90 deg at 316 C, and in the fracture stress, and hence the in-plane shear stress, for those loaded at 45 deg at room temperature. Significant plastic deformation was observed in the 45 deg orientation at 316 C for material produced by both processing methods. In general, fracture occurred by both failure within the matrix and at the fiber-matrix interface; the degree of interfacial failure increased with temperature. Secondary cracking below the primary fracture surface was also observed.

Harper, J.↗

NASA NTRS1985

A review of fracture mechanics life technology

Current lifetime prediction technology for structural components subjected to cyclic loads was reviewed. The central objectives of the project were to report the current state of and recommend future development of fracture mechanics-based analytical tools for modeling and forecasting subcritical fatigue crack growth in structures. Of special interest to NASA was the ability to apply these tools to practical engineering problems and the developmental steps necessary to bring vital technologies to this stage. A survey of published literature and numerous discussions with experts in the field of fracture mechanics life technology were conducted. One of the key points made is that fracture mechanics analyses of crack growth often involve consideration of fatigue and fracture under extreme conditions. Therefore, inaccuracies in predicting component lifetime will be dominated by inaccuracies in environment and fatigue crack growth relations, stress intensity factor solutions, and methods used to model given loads and stresses. Suggestions made for reducing these inaccuracies include: development of improved models of subcritical crack growth, research efforts aimed at better characterizing residual and assembly stresses that can be introduced during fabrication, and more widespread and uniform use of the best existing methods.

Thomas, J. M.↗

NASA NTRS1985

Comparisons of various configurations of the edge delamination test for interlaminar fracture toughness

Various configurations of Edge Delamination Tension (EDT) test specimens, of both brittle (T300/5208) and toughened-matrix (T300/BP907) graphite reinforced composite laminates, were manufactured and tested. The mixed-mode interlaminar fracture toughness, G sub C, was measured using (30/30 sub 2/30/90 sub N)sub s, n=1 or 2, (35/-35/0/90) sub s and (35/0/-35/90) sub s layups designed to delaminate at low tensile strains. Laminates were made without inserts so that delaminations would form naturally between the central 90 deg plies and the adjacent angle plies. Laminates were also made with Teflon inserts implanted between the 90 deg plies and the adjacent angle (theta) plies at the straight edge to obtain a planar fracture surface. In addition, interlaminar tension fracture toughness, GIc, was measured from laminates with the same layup but with inserts in the midplane, between the central 90 deg plies, at the straight edge. All of the EDT configurations were useful for ranking the delamination resistance of composites with different matrix resins. Furthermore, the variety of layups and configurations available yield interlaminar fracture toughness measurements needed to generate delamination failure criteria. The influence of insert thickness and location, and coupon size on G sub c values were evaluated.

Obrien, T. K.↗

NASA NTRS1984

Fracture behavior in silicon

The fracture mechanics of crystalline Si are reviewed, together with known techniques for minimizing the occurences of fracture and/or their effects. The fracture toughness (Kic) of Si varies only 10 percent from cell-to-cell and standard values have been established for different types of crystalline Si cells. A critical flaw size of 10-100 microns has been identified, and also pertains to polycrystalline materials. Chemical polishing is known to double the value of Kic, while edge rounding has no effect. Internal stresses, particularly those caused during ribbon growth, do not exceed 10 percent of Kic. External stresses are imposed by the module hardware and the ambient environment. Multiple contacts reduce the effects of cell fracture and series-parallel wiring in modules in arrays ameliorates the effects of single-cell failures. During manufacturing, maintenance of quality control and removal of sheets displaying aberrations can, depending on the costs and the implementation of the array reliability features, result in arrays delivering any desired level of reliability.

Leipold, M. H.↗

NASA NTRS1984

Application of fracture mechanics on the Space Shuttle

During the design stages of the shuttle orbiter, fracture-mechanics concepts were applied extensively to the highly stressed areas of the structure. This was the first space program to require a comprehensive fracture mechanics approach to prevent structural failures from crack or crack-like defects. As anticipated, some difficult problems were encountered. This paper briefly describes some of them together with the procedure used for fracture control on the orbiter. It is believed that the principles and methods as presented herein can serve as an example of fracture control for aerospace and other industries.

Forman, R. G.↗

NASA NTRS1984

Statistics and thermodynamics of fracture

A probabilistic model of the fracture processes unifying the phenomenological study of long term strength of materials, fracture mechanics and statistical approaches to fracture is briefly outlined. The general framework of irreversible thermodynamics is employed to model the deterministic side of the failure phenomenon. The stochastic calculus is used to account for thg failure mechanisms controlled by chance; particularly, the random roughness of fracture surfaces.

Chudnovsky, A.↗

NASA NTRS1985

Nonlinear quasi-fracture behavior of polymers

This paper deals with the nonlinear quasi-fracture behavior of polymers. Using the finite element method, the quasi-fracture model composed of an isolated craze opening with a nonlinear boundary envelope forces represented by oriented fibril domains is analyzed in simply-stressed rectangular plate. The stress distribution, the displacement profile, as well as the yield or plastic or flow zone adjacent to the craze tips are obtained. It is found that the variation of the stress distribution near the craze tip is not as sharp as that for an elastic crack. The initial load required for yielding or flowing is greater for the quasifracture as compared with that for a classical fracture. Under the same load the yield or flow zone is somewhat smaller as compared with that obtained on the basis of linear elastic-plastic fracture mechanics theory.

Sun, B. N.↗

NASA NTRS1985

Fractography of the interlaminar fracture of carbon-fibre epoxy composites

The failed surfaces of interlaminar fracture (mode I) specimens of AS4/3501-6 were examined using scanning electron microscopy. The principal fracture features were fiber pull-out (bundles and single fibers), hackle markings, and regions of smooth resin fracture. Considerable (30 to 50 percent) relaxation of the deformed resin occurred when the specimens were heated above the matrix glass transition temperature. This relaxation was taken as evidence of extensive shear yielding of the resin during the fracture process. Some of the fractography features are discussed in terms of transverse tensile stresses and peeling stresses acting on the fibers. In some instances these localized stresses focus failure close to the resin-fiber interface, which can be mistakenly interpreted as interfacial failure and low fiber-resin adhesion.

Bascom, W. D.↗

NASA NTRS1986

A review of fracture mechanics life technology

Lifetime prediction technology for structural components subjected to cyclic loads is examined. The central objectives of the project are: (1) to report the current state of the art, and (2) recommend future development of fracture mechanics-based analytical tools for modeling subcritical fatigue crack growth in structures. Of special interest is the ability to apply these tools to practical engineering problems and the developmental steps necessary to bring vital technologies to this stage. The authors conducted a survey of published literature and numerous discussions with experts in the field of fracture mechanics life technology. One of the key points made is that fracture mechanics analyses of crack growth often involve consideration of fatigue and fracture under extreme conditions. Therefore, inaccuracies in predicting component lifetime will be dominated by inaccuracies in environment and fatigue crack growth relations, stress intensity factor solutions, and methods used to model given loads and stresses. Suggestions made for reducing these inaccuracies include development of improved models of subcritical crack growth, research efforts aimed at better characterizing residual and assembly stresses that can be introduced during fabrication, and more widespread and uniform use of the best existing methods.

Besuner, P. M.↗

NASA NTRS1986

Concepts for interrelating ultrasnic attenuation, microstrucutre and fracture toughness in polycrystalline solids

Conceptual models are advanced for explaining and predicting empirical correlations found between ultrasonic measurements and fracture toughness of polycrystalline solids. The models lead to insights concerning microstructural factors governing fracture processes and associated stress wave interactions. Analysis of the empirical correlations suggested by the models indicate that, in addition to grain size and shape, grain boundary reflections, elastic anisotropy, and dislocation damping are factors that underly both fracture toughness and ultrasonic attenuation. One outcome is that ultrasonic attenuation can predict the size of crack blunting or process zones that develop in the vicinity active cracks in metals. This forms a basis for ultrasonic ranking according to variations in fracture toughness.

Vary, A.↗

NASA NTRS1985

Wide-range displacement expressions for standard fracture mechanics specimens

Wide-range algebraic expressions for the displacement of cracked fracture mechanics specimens are developed. For each specimen two equations are given: one for the displacement as a function of crack length, the other for crack length as a function of displacement. All the specimens that appear in ASTM Test for Plane-Strain Fracture Toughness of Metallic Materials (E 399) are represented in addition to the crack mouth displacement for a pure bending specimen. For the compact tension sample and the disk-shaped compact tension sample, the displacement at the crack mouth and at the load line are both considered. Only the crack mouth displacements for the arc-shaped tension samples are presented. The agreement between the displacements or crack lengths predicted by the various equations and the corresponding numerical data from which they were developed are nominally about 3 percent or better. These expressions should be useful in all types of fracture testing including fracture toughness, K-resistance, and fatigue crack growth.

Kapp, J. A.↗

NASA NTRS1985

An evaluation of fracture analysis methods

The results of an experimental and predictive round robin on the applications of fracture analysis methods are presented. The objective of the round robin was to verify whether fracture analysis methods currently in use can or cannot predict failure loads on complex structural components containing cracks. Fracture results from tests on a number of compact specimens were used to make the predictions. The accuracy of the prediction methods was evaluated in terms of the variation in the ratio of predicted to experimental failure loads, and the predictions methods are ranked in order of minimum standard error. A range of applicability of the different methods was also considered in assessing their usefulness. For 7075-T651 aluminum alloy, the best methods were: the effective K sub R curve; the critical crack-tip opening displacement (CTOD) criterion using a finite element analysis; and the K sub R curve with the Dugdale model. For the 2024-T351 aluminum alloy, the best methods included: the two-parameter fracture criterion (TPFC); the CTOD parameter using finite element analysis; the K-curve with the Dugdale model; the deformation plasticity failure assessment diagram (DPFAD); and the effective K sub R curve with a limit load condition. For 304 stainless steel, the best methods were the limit load analysis; the CTOD criterion using finite-element analysis TPFC and DPFAD. Some sample experimental results are given in an appendix.

Newman, J. C., Jr.↗

NASA NTRS1986

Progressive fracture of fiber composites

Refined models and procedures are described for determining progressive composite fracture in graphite/epoxy angleplied laminates. Unique Lewis Research Center capabilities are utilized including the Real-Time Ultrasonic C-San (RUSCAN) experimental facility and the Composite Durability Structural Analysis (CODSTRAN) computer code. CODSTRAN is used to predict the fracture progression based on composite mechanics, finite element stress analysis, and fracture criteria modules. The RUSCAN facility, CODSTRAN computer code, and scanning electron microscope are used to determine durability and identify failure mechanisms in graphite/epoxy coomposites. Results indicate that RUSCAN/CODSTRAN is an effective method of Studying progressive fracture of composites.

Irvine, T. B.↗

NASA NTRS1987

The effect of overburden thickness on tension fracture patterns above an uplifting dome

Four experiments demonstrate that tension-fracture patterns above an uplifting dome depend on the thickness of the overburden layer being deformed. Four layers of increasing thicknesses (4.92 cm, 6.92 cm, 9.05 cm, and 11.12 cm) of a very fine sand (85%) and silt-clay (15%) mixture were updomed by slowly inflating a 1.22 m-diameter circular rubber pillow. The upper 2 cm of each layer was wetted and air dried to make it brittle and susceptible to fracture. The fractures that formed during these experiments exhibited a continuum of patterns from dominantly arcuate to dominantly radial as the overburden thickness increased. However, fracture density remained constant in each case for a given amount of surface deformation.

Pranger, H., II↗

NASA NTRS1985

Fracture strength of GaAs solar cells as a function of manufacturing process steps

Fracture of single crystal GaAs substrate during the solar cell processing is an important factor in solar cell yield and cost. Fracture mechanics technique was utilized to evaluate cell cracking characteristics and changes in fracture strength of GaAs solar cells in a present state-of-the-art of manufacturing process for GaAs solar cells from wafer to complete cell of a typical production line. Considerable change in the fracture strength of GaAs solar cells as a function of cell processing was found. The strength data were described by Weibull statistical analysis and can be interpreted with the change of flaw distribution of each of the manufacturing process steps.

Chen, C. P.↗