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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Non-Linear Analysis of the NASA Super Pressure Balloons: Whole Flight Simulations

Tensys have a long-established background in the shape generation and load analysis of architectural stressed membrane structures. Founded upon their inTENS finite element analysis suite, these activities have broadened to encompass 'lighter than air' structures such as aerostats, airships, hybrid air vehicles and stratospheric balloons. Tensys have acted as consultants to the NASA Super Pressure Balloon (SPB) Program since 2004. Previous papers have focussed upon the application of inTENS to the overall structural and stability analysis of pumpkin type balloons as used in the SPB Program. Particular emphasis has been placed upon the ability to study both stress and stability at all stages of a flight. As the program has developed, increasing modelling fidelity has been introduced as design refinement has moved emphasis from the overall shape to the performance of individual details. Examples include the introduction of a contact capability into inTENS to better represent the separate cap layer of film. Localised investigations have considered the consequence of local geometric anomalies introduced during fabrication and the effects of debonding of the PBO tendon within its sleeve. Analysis to date has used a material model for the polyethylene shell film developed by Dr Rand of Winzen Engineering, supported by a program of fine resolution material tests at the Balloon Research and Development Laboratory (BRDL) at the GSFC Wallops Island Facility. Based upon work first reported by Schapery, this model has been incorporated into so-called 'snapshot' analyses within inTENS. For a given elapsed time point and temperature distribution, non-linear material properties are iteratively updated for the current stress state in each individual element until changes in those material properties are insignificant. This process has to be iterative as the film stresses and material properties are interdependent. Attempts to derive a time-stepping incremental viscoelastic capability using the Schapery Rand model encountered problems when dealing with the varying temperatures associated with balloon deployment, pressurisation and diurnal behaviour. An alternative approach has been developed by Pellegrino et al at Caltech, again with support from the NASA Balloon Program Office. This is a large strain non-linear viscoelastic model that includes film out-of-plane mechanical and thermal effects. Working from a unified base, this model can be utilised for time-stepping analyses in both a modulus or compliance mode, or a combination of both. This new capability is intended to enhance the current NASA balloon design process. This paper presents the implementation of the Caltech model into a specialist finite element suite, inTENS and its application to whole flight simulations.

Wakefield, David↗
NASA NTRS2016

Fatigue Analysis of Notched Laminates: A Time-Efficient Macro-Mechanical Approach

A coupled transversely isotropic deformation and damage fatigue model is implemented within the finite element method and was utilized along with a static progressive damage model to predict the fatigue life, stiffness degradation as a function of number of cycles, and post-fatigue tension and compression response of notched, multidirectional laminates. Initially, the material parameters for the fatigue model were obtained utilizing micromechanics simulations and the provided [0], [90] and [plus or minus 45] experimental composite laminate S-N (stress-cycle) data. Within the fatigue damage model, the transverse and shear properties of the plies were degraded with an isotropic scalar damage variable. The damage in the longitudinal (fiber) ply direction was suppressed, and only the strength of the fiber was degraded as a function of fatigue cycles. A maximum strain criterion was used to capture the failure in each element, and once this criterion was satisfied, the longitudinal stiffness of the element was decreased by a factor of 10 (sup 4). The resulting, degraded properties were then used to calculate the new stress state. This procedure was repeated until final failure of the composite laminate was achieved or a specified number of cycles reached. For post-fatigue tension and compression behavior, four internal state variables were used to control the damage and failure. The predictive capability of the above-mentioned approach was assessed by performing blind predictions of the notched multidirectional IM7/977-3 composite laminates response under fatigue and post-fatigue tensile and compressive loading, followed by a recalibration phase. Although three different multidirectional laminates were analyzed in the course of this study, only detailed results (i.e., stiffness degradation and post-fatigue stress-train curves as well as damage evolution states for a single laminate ([30/60/90/minus 30/minus 60] (sub 2s)) are discussed in detail here.

Composite Fatigue analysis↗
DOE OSTI2024

Effects of Plume Targeted Cooling on Residual Stress in Controlled Atmosphere Plasma Sprayed Coatings

Thermal spray processes can benefit from cooling to maintain substrate temper, reduce processing times, and manage thermally induced residual stresses. “Plume quenching” is a plume-targeted cooling technique which has been shown to reduce substrate temperatures by redirection of hot plume gases using a lateral argon curtain injected into the plume, while limiting interaction with the substrate or affecting coating properties. Here, this study explores the use of this technique for residual stress management by reducing the thermally driven component in nickel and tantalum coatings on titanium and aluminum substrates. The in-situ residual stress profiles were measured for all substrate and coating pairings during spraying and cooling, and the deposition and thermal stresses recorded. For substrate and coating pairings where the predominant component of residual stress was thermal (driven by a large difference in coefficient of thermal expansion, Δα, between coating and substrate), plume quenching reduced both the thermal stress and the final stress state of the coating. This was seen primarily in tantalum on aluminum coatings where the Δα was -17 × 10 -6 /°C, and thermal stress was reduced by 7.5% and 22.4% for the plume quenching rates of 50 and 100 slpm, respectively.

42 ENGINEERING↗
NASA NTRS1981

Stress generation in thermally grown oxide films

A three dimensional finite element analysis was conducted, using the ANSYS computer program, of the stress state in a thin oxide film thermally formed on a rectangular piece of NiCrAl alloy. The analytical results indicate a very high compressive stress in the lateral directions of the film (approximately 6200 MPa), and tensile stresses in the metal substrate that ranged from essentially zero to about 55 MPa. It was found further that the intensity of the analytically determined average stresses could be approximated reasonably well by the modification of an equation developed previously by Oxx for stresses induced into bodies by thermal gradients.

Kumnick, A. J.↗
NASA NTRS1985

A clamped rectangular plate containing a crack

The general problem of a rectangular plate clamped along two parallel sides and containing a crack parallel to the clamps is considered. The problem is formulated in terms of a system of singular integral equations and the asymptotic behavior of the stress state near the corners is investigated. Numerical examples are considered for a clamped plate without a crack and with a centrally located crack, and the stress intensity factors and the stresses along the clamps are calculated.

Tang, R.↗
NASA NTRS1985

A clamped rectangular plate containing a crack

The general problem of a rectangular plate clamped along two parallel sides and containing a crack parallel to the clamps is considered. The problem is formulated in terms of a system of singular integral equations and the asymptotic behavior of the stress state near the corners is investigated. Numerical examples are considered for a clamped plate without a crack and with a centrally located crack, and the stress intensity factors and the stresses along the clamps are calculated.

Tang, R.↗
DOE OSTI2026

Mapping the Residual Stress Distribution in Polycrystalline Quartz Tiger's Eye Using Raman Spectroscopy

Stress distribution maps in polycrystalline materials are needed to reveal stress pathways caused by short‐and long‐range interactions of crystallites. Stress induced changes to wavenumbers in Raman spectroscopy is a well‐known phenomenon that occurs when a crystalline material undergoes elastic strain. Using spatially resolved Raman spectroscopy, we have developed a technique to experimentally measure grain‐scale residual stresses across a sample of polycrystal quartz Tiger's Eye. The results of this technique are validated using multiple criteria, including evaluation of the residual stress map itself and the accuracy of the measurements taken. The residual map of Tiger's Eye shows striking similarity to observed characteristics of other polycrystalline residual stress distributions, revealing heterogenous areas of high and low magnitude stresses. The stress magnitudes are consistent with residual stress magnitudes previously measured from polycrystalline quartz. Characterization of Tiger's Eye quartz also revealed the geometric nature of the iron oxide inclusions, not previously observed in Tiger's Eye quartz. With this technique, we present a residual stress map of Tiger's Eye quartz that shows with accuracy a heterogeneous stress state with inter‐ and intra‐granular detail.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multiscale Shear Properties and Flow Performance of Milled Woody Biomass

One dominant challenge facing the development of biorefineries is achieving consistent system throughput with highly variant biomass feedstock quality and handling performance. Current handling unit operations are adapted from other sectors (primarily agriculture), where some simplifying assumptions about granular mechanics and flow performance do not translate well to a highly compressible and anisotropic material with nonlinear time- and stress-dependent properties. This work explores the shear and frictional properties of loblolly pine at multiple experimental test apparatus and particle scales to elucidate a property window that defines the shear behavior over a range of material attributes (particle size, size distribution, moisture content, etc.). In general, it was observed that the bulk internal friction and apparent cohesion depend strongly on both the stress state of the sample in granular shear testers and the overall particle size and distribution span. For equipment designed to characterize the quasi-static shear stress failure of bulk materials ranging from 50 to 1,000 ml in test volume, similar test results were observed for finely milled particles (50% passing size of 1.4 mm) with a narrow size distribution (span between 10 and 90% passing size of 0.9 mm), while stress chaining and over-torque issues persisted for the bench-scale test apparatus for larger particle sizes or widely dispersed sample sizes. Measurement of the anisotropic particle–particle friction ranged from coefficients of approximately 0.20 to 0.45 and resulted in significantly higher and more variable friction measurements for larger particle sizes and in perpendicular alignment orientations. To supplement these laboratory-scale properties, this work explores the flow of loblolly pine and Douglas fir through a pilot-scale wedge-shaped hopper and a screw feeder. For the gravity-driven hopper flow, the critical arching distance and mass discharge rate ranged from approximately 10 to 30 mm and 2 to 16 tons/hour, respectively, for both materials, where the arching distance depends strongly on the overall particle size and depends less on the hopper inclination angle. Comparatively, the auger feeder was found to be much more impacted by the size of the particles, where smaller particles had a more consistent and stable flow while consuming less power.

09 BIOMASS FUELS↗
NASA NTRS1984

The crack-inclusion interaction problem

The general plane elastostatic problem of interaction between a crack and an inclusion is considered. The Green's functions for a pair of dislocations and a pair of concentrated body forces are used to generate the crack and the inclusion. Integral equations are obtained for a line crack and an elastic line inclusion having an arbitrary relative orientation and size. The nature of stress singularity around the end points of rigid and elastic inclusions is described and three special cases of this intersection problem are studied. The problem is solved for an arbitrary uniform stress state away from the crack-inclusion region. The nonintersecting crack-inclusion problem is considered for various relative size, orientation, and stiffness parameters, and the stress intensity factors at the ends of the inclusion and the crack are calculated. For the crack-inclusion intersection case, special stress intensity factors are defined and are calculated for various values of the parameters defining the relative size and orientation of the crack and the inclusion and the stiffness of the inclusion.

Xue-Hui, L.↗
NASA NTRS1986

The crack-inclusion interaction problem

The general plane elastostatic problem of interaction between a crack and an inclusion is considered. The Green's functions for a pair of dislocations and a pair of concentrated body forces are used to generate the crack and the inclusion. Integral equations are obtained for a line crack and an elastic line inclusion having an arbitrary relative orientation and size. The nature of stress singularity around the end points of rigid and elastic inclusions is described and three special cases of this intersection problem are studied. The problem is solved for an arbitrary uniform stress state away from the crack-inclusion region. The nonintersecting crack-inclusion problem is considered for various relative size, orientation, and stiffness parameters, and the stress intensity factors at the ends of the inclusion and the crack are calculated. For the crack-inclusion intersection case, special stress intensity factors are defined and are calculated for various values of the parameters defining the relative size and orientation of the crack and the inclusion and the stiffness of the inclusion.

Liu, X.-H.↗
NASA NTRS1993

A study of fiber volume fraction effects in notched unidirectional SCS-6/Ti-15V-3Cr-3Al-3Sn composite

Notched unidirectional SCS-6/Ti-15-3 composite of three different fiber volume fractions (vf = 0.15, 0.37, and 0.41) was investigated for various room temperature microstructural and material properties including: fatigue crack initiation, fatigue crack growth, and fracture toughness. While the matrix hardness is similar for all fiber volume fractions, the fiber/matrix interfacial shear strength and matrix residual stress increases with fiber volume fraction. The composite fatigue crack initiation stress is shown to be matrix controlled and occurs when the net maximum matrix stress approaches the endurance limit stress of the matrix. A model is presented which includes residual stresses and presents the composite initiation stress as a function of fiber volume fraction. This model predicts a maximum composite initiation stress at vf approximately 0.15 which agrees with the experimental data. The applied composite stress levels were increased as necessary for continued crack growth. The applied Delta(K) values at crack arrest increase with fiber volume fraction by an amount better approximated using an energy based formulation rather than when scaled linear with modulus. After crack arrest, the crack growth rate exponents for vf37 and vf41 were much lower and toughness much higher, when compared to the unreinforced matrix, because of the bridged region which parades with the propagating fatigue crack. However, the vf15 material exhibited a higher crack growth rate exponent and lower toughness than the unreinforced matrix because once the bridged fibers nearest the crack mouth broke, the stress redistribution broke all bridged fibers, leaving an unbridged crack. Degraded, unbridged behavior is modeled using the residual stress state in the matrix ahead of the crack tip. Plastic zone sizes were directly measured using a metallographic technique and allow prediction of an effective matrix stress intensity which agrees with the fiber pressure model if residual stresses are considered. The sophisticated macro/micro finite element models of the 0.15 and 0.37 fiber volume fractions presented show good agreement with experimental data and the fiber pressure model when an estimated effective fiber/matrix debond length is used.

Covey, Steven J.↗
NASA NTRS2010

Composite Overwrapped Pressure Vessels (COPV): Developing Flight Rationale for the Space Shuttle Program

Introducing composite vessels into the Space Shuttle Program represented a significant technical achievement. Each Orbiter vehicle contains 24 (nominally) Kevlar tanks for storage of pressurized helium (for propulsion) and nitrogen (for life support). The use of composite cylinders saved 752 pounds per Orbiter vehicle compared with all-metal tanks. The weight savings is significant considering each Shuttle flight can deliver 54,000 pounds of payload to the International Space Station. In the wake of the Columbia accident and the ensuing Return to Flight activities, the Space Shuttle Program, in 2005, re-examined COPV hardware certification. Incorporating COPV data that had been generated over the last 30 years and recognizing differences between initial Shuttle Program requirements and current operation, a new failure mode was identified, as composite stress rupture was deemed credible. The Orbiter Project undertook a comprehensive investigation to quantify and mitigate this risk. First, the engineering team considered and later deemed as unfeasible the option to replace existing all flight tanks. Second, operational improvements to flight procedures were instituted to reduce the flight risk and the danger to personnel. Third, an Orbiter reliability model was developed to quantify flight risk. Laser profilometry inspection of several flight COPVs identified deep (up to 20 mil) depressions on the tank interior. A comprehensive analysis was performed and it confirmed that these observed depressions were far less than the criterion which was established as necessary to lead to liner buckling. Existing fleet vessels were exonerated from this failure mechanism. Because full validation of the Orbiter Reliability Model was not possible given limited hardware resources, an Accelerated Stress Rupture Test of a flown flight vessel was performed to provide increased confidence. A Bayesian statistical approach was developed to evaluate possible test results with respect to the model credibility and thus flight rationale for continued operation of the Space Shuttle with existing flight hardware. A non-destructive evaluation (NDE) technique utilizing Raman Spectroscopy was developed to directly measure the overwrap residual stress state. Preliminary results provide optimistic results that patterns of fluctuation in fiber elastic strains over the outside vessel surface could be directly correlated with increased fiber stress ratios and thus reduced reliability.

Kezirian, Michael T.↗
NASA NTRS1990

Damage states in laminated composite three-point bend specimens: An experimental-analytical correlation study

Damage states in laminated composites were studied by considering the model problem of a laminated beam subjected to three-point bending. A combination of experimental and theoretical research techniques was used to correlate the experimental results with the analytical stress distributions. The analytical solution procedure was based on the stress formulation approach of the mathematical theory of elasticity. The solution procedure is capable of calculating the ply-level stresses and beam displacements for any laminated beam of finite length using the generalized plane deformation or plane stress state assumption. Prior to conducting the experimental phase, the results from preliminary analyses were examined. Significant effects in the ply-level stress distributions were seen depending on the fiber orientation, aspect ratio, and whether or not a grouped or interspersed stacking sequence was used. The experimental investigation was conducted to determine the different damage modes in laminated three-point bend specimens. The test matrix consisted of three-point bend specimens of 0 deg unidirectional, cross-ply, and quasi-isotropic stacking sequences. The dependence of the damage initiation loads and ultimate failure loads were studied, and their relation to damage susceptibility and damage tolerance of the mean configuration was discussed. Damage modes were identified by visual inspection of the damaged specimens using an optical microscope. The four fundamental damage mechanisms identified were delaminations, matrix cracking, fiber breakage, and crushing. The correlation study between the experimental results and the analytical results were performed for the midspan deflection, indentation, damage modes, and damage susceptibility.

Starbuck, J. Michael↗
NASA NTRS1976

On the problem of stress singularities in bonded orthotropic materials

The problem of stress singularities at the leading edge of a crack lying in the neighborhood of a bimaterial interface in bonded orthotropic materials is considered. The main objective is to study the effect of material orthotropy on the singular behavior of the stress state when the crack touches or intersects the interface. The results indicate that, due to the large number of material constants involved, in orthotropic materials, the power of stress singularity as well as the stress intensity factor can be considerably different than that found in the isotropic materials with the same stiffness ratio perpendicular to the crack.

Erdogan, F.↗
NASA NTRS1988

Fatigue damage mapping

Observations of fatigue crack nucleation and early growth are presented. The state of stress/strain was shown to play a significant role in this process. Early growth occurs on planes experiencing the largest range of shear strain (Mode 2) or normal strain (Mode 1) depending on the stress state, strain amplitude, and microstructure. These observations were summarized in a fatigue map for each material. These maps provide regions where one fatigue failure mode dominates the behavior. Each failure mechanism results in a different failure mode. Once the expected failure mode is identified, bulk deformation models based on the cyclic stresses and strains can be used to obtain reliable estimates of fatigue lives for complex loading situations.

Socie, Darrell↗