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At least 289 records · Page 16

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NASA NTRS1992

Application of fiber bridging models to fatigue crack growth in unidirectional titanium matrix composites

Several fiber bridging models were reviewed and applied to study the matrix fatigue crack growth behavior in center notched (0)(sub 8) SCS-6/Ti-15-3 and (0)(sub 4) SCS-6/Ti-6Al-4V laminates. Observations revealed that fatigue damage consisted primarily of matrix cracks and fiber matrix interfacial failure in the (0)(sub 8) SCS-6/Ti-15-3 laminates. Fiber-matrix interface failure included fracture of the brittle reaction zone and cracking between the two carbon rich fiber coatings. Intact fibers in the wake of the matrix cracks reduce the stress intensity factor range. Thus, an applied stress intensity factor range is inappropriate to characterize matrix crack growth behavior. Fiber bridging models were used to determine the matrix stress intensity factor range in titanium metal matrix composites. In these models, the fibers in the wake of the crack are idealized as a closure pressure. An unknown constant frictional shear stress is assumed to act along the debond or slip length of the bridging fibers. The frictional shear stress was used as a curve fitting parameter to available data (crack growth data, crack opening displacement data, and debond length data). Large variations in the frictional shear stress required to fit the experimental data indicate that the fiber bridging models in their present form lack predictive capabilities. However, these models provide an efficient and relatively simple engineering method for conducting parametric studies of the matrix growth behavior based on constituent properties.

Bakuckas, J. G., Jr.↗

NASA NTRS1991

Stability analysis of bridged cracks in brittle matrix composites

The bridging of matrix cracks by fibers is an important toughening mechanism in fiber reinforced brittle matrix composites. This paper presents the results of a nonlinear finite element analysis of the Mode-I propagation of a bridged matrix crack in a finite size specimen. The composite is modeled as an orthotropic continuum and the bridging due to the fibers is modeled as a distribution of tractions which resist crack opening. A critical stress intensity factor criterion is employed for matrix crack propagation while a critical crack opening condition is used for fiber failure. The structural response of the specimen (load-deflection curves) as well as the stress intensity factor of the propagating crack are calculated for various constituent properties and specimen configurations for both tensile and bending loading. By controlling the length of the bridged crack results are obtained which highlight the transition from stable to unstable behavior of the propagating crack.

Ballarini, Roberto↗

NASA NTRS1991

Effective crack lengths by compliance measurement for ARALL-2 laminates

As a means of determining a stress intensity factor solution, the compliance properties of an ARALL-2 laminated-sheet composite were investigated. Fatigue crack growth rate (FCGR) tests were conducted on middle crack tension (MT) specimens fabricated from a layup consisting of three sheets of 2024-T3 aluminum bonded together with unidirectional aramid fibers embedded in epoxy. Excellent fatigue crack growth properties are obtained by the presence of unbroken aramid fibers in the wake of the crack tip. These unbroken fibers act as a bridging mechanism to inhibit further crack growth. To quantify the effect of maximum fatigue load on compliance, a series of FCGR tests were performed. Effective crack lengths were determined to be at least 10 mm shorter than surface measured crack lengths for a 76-mm-wide specimen. The bridging zone was estimated to be at least 5 mm. Compliance and stress intensity factor as functions of effective crack length were determined.

Wilson, Christopher D.↗

NASA NTRS1992

An energy analysis of crack-initiation and arrest in epoxy

The objective of this work is to study fracture processes such as crack initiation and arrest in epoxy. A compact tension specimen with displacement-controlled loading is employed to observe multiple crack initiations and arrests. The energy release rate at crack initiation is significantly higher than that at crack arrest, as has been observed elsewhere. In this study, the difference between these energy release rates is found to depend on specimen size (scale effect), and is quantitatively related to the fracture surface morphology. The scale effect, similar to that in strength theory, is conventionally attributed to the statistics of defects which control the fracture process. Triangular shaped ripples, deltoids, are formed on the fracture surface of the epoxy during the slow sub-critical crack growth, prior to the smooth mirrorlike surface characteristic of fast cracks. The deltoids are complimentary on the two crack faces which excludes any inelastic deformation from consideration. The deltoids are analogous to the ripples created on a river surface downstream from a small obstacle. However, in spite of the expectation based on this analogy and the observed scale effect, there are no 'defects' at the apex of the deltoids detectable down to the 0.1 micron level. This suggests that the formation of deltoids during the slow process of subcritical crack growth is an intrinsic feature of the fracture process itself, triggered by inhomogeneity of material on a submicron scale. This inhomogeneity may be related to a fluctuation in the cross-link density of the epoxy.

Chudnovsky, A.↗

NASA NTRS1993

Three-dimensional elastic-plastic finite-element analyses of constraint variations in cracked bodies

Three-dimensional elastic-plastic (small-strain) finite-element analyses were used to study the stresses, deformations, and constraint variations around a straight-through crack in finite-thickness plates for an elastic-perfectly plastic material under monotonic and cyclic loading. Middle-crack tension specimens were analyzed for thicknesses ranging from 1.25 to 20 mm with various crack lengths. Three local constraint parameters, related to the normal, tangential, and hydrostatic stresses, showed similar variations along the crack front for a given thickness and applied stress level. Numerical analyses indicated that cyclic stress history and crack growth reduced the local constraint parameters in the interior of a plate, especially at high applied stress levels. A global constraint factor alpha(sub g) was defined to simulate three-dimensional effects in two-dimensional crack analyses. The global constraint factor was calculated as an average through-the-thickness value over the crack-front plastic region. Values of alpha(sub g) were found to be nearly independent of crack length and were related to the stress-intensity factor for a given thickness.

Newman, J. C., Jr.↗

NASA NTRS1992

Fracture mechanics parameters for small fatigue cracks

This paper presents a review of some common small-crack test specimens, the underlying causes of the small-crack effect, and the fracture-mechanics parameters that have been used to correlate or predict their growth behavior. This review concentrates on continuum mechanics concepts and on the nonlinear behavior of small cracks. The paper reviews some stress-intensity factor solutions for small-crack test specimens and develops some simple elastic-plastic J integral and cyclic J integral expressions that include the influence of crack-closure. These parameters were applied to small-crack growth data on two aluminum alloys, and a fatigue life prediction methodology is demonstrated. For these materials, the crack-closure transient from the plastic wake was found to be the major factor in causing the small-crack effect.

Newman, J. C., Jr.↗

NASA NTRS1993

Environment enhanced fatigue crack propagation in metals: Inputs to fracture mechanics life prediction models

This report is a critical review of both environment-enhanced fatigue crack propagation data and the predictive capabilities of crack growth rate models. This information provides the necessary foundation for incorporating environmental effects in NASA FLAGRO and will better enable predictions of aerospace component fatigue lives. The review presents extensive literature data on 'stress corrosion cracking and corrosion fatigue.' The linear elastic fracture mechanics approach, based on stress intensity range (Delta(K)) similitude with microscopic crack propagation threshold and growth rates, provides a basis for these data. Results are presented showing enhanced growth rates for gases (viz., H2 and H2O) and electrolytes (e.g. NaCl and H2O) in aerospace alloys including: C-Mn and heat treated alloy steels, aluminum alloys, nickel-based superalloys, and titanium alloys. Environment causes purely time-dependent accelerated fatigue crack growth above the monotonic load cracking threshold (KIEAC) and promotes cycle-time dependent cracking below (KIEAC). These phenomenon are discussed in terms of hydrogen embrittlement, dissolution, and film rupture crack tip damage mechanisms.

Gangloff, Richard P.↗

NASA NTRS1993

Fatigue life and crack growth prediction methodology

The capabilities of a plasticity-induced crack-closure model and life-prediction code to predict fatigue crack growth and fatigue lives of metallic materials are reviewed. Crack-tip constraint factors, to account for three-dimensional effects, were selected to correlate large-crack growth rate data as a function of the effective-stress-intensity factor range (delta(K(sub eff))) under constant-amplitude loading. Some modifications to the delta(K(sub eff))-rate relations were needed in the near threshold regime to fit small-crack growth rate behavior and endurance limits. The model was then used to calculate small- and large-crack growth rates, and in some cases total fatigue lives, for several aluminum and titanium alloys under constant-amplitude, variable-amplitude, and spectrum loading. Fatigue lives were calculated using the crack growth relations and microstructural features like those that initiated cracks. Results from the tests and analyses agreed well.

Newman, J. C., Jr.↗

NASA NTRS1994

The Role of Crack Formation in Chevron-Notched Four-Point Bend Specimens

The failure sequence following crack formation in a chevron-notched four-point bend 1 specimen is examined in a parametric study using the Bluhm slice synthesis model. Premature failure resulting from crack formation forces which exceed those required to propagate a crack beyond alpha (min) is examined together with the critical crack length and critical crack front length. An energy based approach is used to establish factors which forecast the tendency of such premature failure due to crack formation for any selected chevron-notched geometry. A comparative study reveals that, for constant values of alpha (1) and alpha (0), the dimensionless beam compliance and stress intensity factor are essentially independent of specimen width and thickness. The chevron tip position, alpha (0) has its primary effect on the force required to initiate a sharp crack. Small values for alpha (0) maximize the stable region length, however, the premature failure tendency is also high for smaller alpha (0) values. Improvements in premature failure resistance can be realized for larger values of alpha (0) with only a minor reduction in the stable region length. The stable region length is also maximized for larger chevron based positions, alpha (1) but the chance for premature failure is also raised. Smaller base positions improve the premature failure resistance with only minor decreases in the stable region length. Chevron geometries having a good balance of premature failure resistance, stable region length, and crack front length are 0.20 less than or equal to alpha (0) is less than or equal to 0.30 and 0.70 is less than or equal to alpha (1) is less than or equal to 0.80.

Calomino, Anthony M.↗

NASA NTRS1994

Recent advances in the modelling of crack growth under fatigue loading conditions

Fatigue crack growth associated with cyclic (secondary) plastic flow near a crack front is modelled using an incremental formulation. A new description of threshold behaviour under small load cycles is included. Quasi-static crack extension under high load excursions is described using an incremental formulation of the R-(crack growth resistance)- curve concept. The integration of the equations is discussed. For constant amplitude load cycles the results will be compared with existing crack growth laws. It will be shown that the model also properly describes interaction effects of fatigue crack growth and quasi-static crack extension. To evaluate the more general applicability the model is included in the NASGRO computer code for damage tolerance analysis. For this purpose the NASGRO program was provided with the CORPUS and the STRIP-YIELD models for computation of the crack opening load levels. The implementation is discussed and recent results of the verification are presented.

Dekoning, A. U.↗

NASA NTRS1994

Modeling time-dependent corrosion fatigue crack propagation in 7000 series aluminum alloys

Stress corrosion cracking and corrosion fatigue experiments were conducted with the susceptible S-L orientation of AA7075-T651, immersed in acidified and inhibited NaCl solution, to provide a basis for incorporating environmental effects into fatigue crack propagation life prediction codes such as NASA FLAGRO. This environment enhances da/dN by five to ten-fold compared to fatigue in moist air. Time-based crack growth rates from quasi-static load experiments are an order of magnitude too small for accurate linear superposition prediction of da/dN for loading frequencies above 0.001 Hz. Alternate methods of establishing da/dt, based on rising-load or ripple-load-enhanced crack tip strain rate, do not increase da/dt and do not improve linear superposition. Corrosion fatigue is characterized by two regimes of frequency dependence; da/dN is proportional to f(exp -1) below 0.001 Hz and to F(exp 0) to F(exp -0.1) for higher frequencies. Da/dN increases mildly both with increasing hold-time at K(sub max) and with increasing rise-time for a range of loading waveforms. The mild time-dependence is due to cycle-time-dependent corrosion fatigue growth. This behavior is identical for S-L nd L-T crack orientations. The frequency response of environmental fatigue in several 7000 series alloys is variable and depends on undefined compositional or microstructural variables. Speculative explanations are based on the effect of Mg on occluded crack chemistry and embritting hydrogen uptake, or on variable hydrogen diffusion in the crack tip process zone. Cracking in the 7075/NaCl system is adequately described for life prediction by linear superposition for prolonged load-cycle periods, and by a time-dependent upper bound relationship between da/dN and delta K for moderate loading times.

Mason, Mark E.↗

NASA NTRS1996

Detecting Gear Tooth Fatigue Cracks in Advance of Complete Fracture

Results of using vibration-based methods to detect gear tooth fatigue cracks are presented. An experimental test rig was used to fail a number of spur gear specimens through bending fatigue. The gear tooth fatigue crack in each test was initiated through a small notch in the fillet area of a tooth on the gear. The primary purpose of these tests was to verify analytical predictions of fatigue crack propagation direction and rate as a function of gear rim thickness. The vibration signal from a total of three tests was monitored and recorded for gear fault detection research. The damage consisted of complete rim fracture on the two thin rim gears and single tooth fracture on the standard full rim test gear. Vibration-based fault detection methods were applied to the vibration signal both on-line and after the tests were completed. The objectives of this effort were to identify methods capable of detecting the fatigue crack and to determine how far in advance of total failure positive detection was given. Results show that the fault detection methods failed to respond to the fatigue crack prior to complete rim fracture in the thin rim gear tests. In the standard full rim gear test all of the methods responded to the fatigue crack in advance of tooth fracture; however, only three of the methods responded to the fatigue crack in the early stages of crack propagation.

Zakrajsek, James J.↗

NASA NTRS1997

Fatigue-Life Prediction Methodology Using Small-Crack Theory

This paper reviews the capabilities of a plasticity-induced crack-closure model to predict fatigue lives of metallic materials using 'small-crack theory' for various materials and loading conditions. Crack-tip constraint factors, to account for three-dimensional state-of-stress effects, were selected to correlate large-crack growth rate data as a function of the effective-stress-intensity factor range (delta K(eff)) under constant-amplitude loading. Some modifications to the delta k(eff)-rate relations were needed in the near-threshold regime to fit measured small-crack growth rate behavior and fatigue endurance limits. The model was then used to calculate small- and large-crack growth rates, and to predict total fatigue lives, for notched and un-notched specimens made of two aluminum alloys and a steel under constant-amplitude and spectrum loading. Fatigue lives were calculated using the crack-growth relations and microstructural features like those that initiated cracks for the aluminum alloys and steel for edge-notched specimens. An equivalent-initial-flaw-size concept was used to calculate fatigue lives in other cases. Results from the tests and analyses agreed well.

Newmann, James C., Jr.↗

NASA NTRS1998

Residual Strength Pressure Tests and Nonlinear Analyses of Stringer-and Frame-Stiffened Aluminum Fuselage Panels with Longitudinal Cracks

The results of residual strength pressure tests and nonlinear analyses of stringer- and frame-stiffened aluminum fuselage panels with longitudinal cracks are presented. Two types of damage are considered: a longitudinal crack located midway between stringers, and a longitudinal crack adjacent to a stringer and along a row of fasteners in a lap joint that has multiple-site damage (MSD). In both cases, the longitudinal crack is centered on a severed frame. The panels are subjected to internal pressure plus axial tension loads. The axial tension loads are equivalent to a bulkhead pressure load. Nonlinear elastic-plastic residual strength analyses of the fuselage panels are conducted using a finite element program and the crack-tip-opening-angle (CTOA) fracture criterion. Predicted crack growth and residual strength results from nonlinear analyses of the stiffened fuselage panels are compared with experimental measurements and observations. Both the test and analysis results indicate that the presence of MSD affects crack growth stability and reduces the residual strength of stiffened fuselage shells with long cracks.

Young, Richard D.↗

NASA NTRS1999

Residual Strength Pressure Tests and Nonlinear Analyses of Stringer- and Frame-Stiffened Aluminum Fuselage Panels with Longitudinal Cracks

Young, Richard D.↗

NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

The objectives were to create a capability to simulate curvilinear crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage and to validate with tests. Analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically, while insuring continuous airworthiness, and to design more damage-tolerant aircraft for the next generation. Simulations of crack growth in fuselages were described. The crack tip opening angle (CTOA) fracture criterion, obtained from laboratory tests, was used to predict fracture behavior of fuselage panel tests. Geometrically nonlinear, elastic-plastic, thin shell finite element crack growth analyses were conducted. Comparisons of stress distributions, multiple stable crack growth history, and residual strength between measured and predicted results were made to assess the validity of the methodology. Incorporation of residual plastic deformations and tear strap failure was essential for accurate residual strength predictions. Issue related to predicting crack trajectory in fuselages were also discussed. A directional criterion, including T-stress and fracture toughness orthotropy, was developed. Curvilinear crack growth was simulated in coupon and fuselage panel tests. Both T-stress and fracture toughness orthotropy were essential to predict the observed crack paths. Flapping of fuselages were predicted. Measured and predicted results agreed reasonable well.

Chen, Chuin-Shan↗

NASA NTRS2000

Simulating Fatigue Crack Growth in Spiral Bevel Gears

The majority of helicopter transmission systems utilize spiral bevel gears to convert the horizontal power from the engine into vertical power for the rotor. Due to the cyclical loading on a gear's tooth, fatigue crack propagation can occur. In rotorcraft applications, a crack's trajectory determines whether the gear failure will be benign or catastrophic for the aircraft. As a result, the capability to predict crack growth in gears is significant. A spiral bevel gear's complex shape requires a three dimensional model of the geometry and cracks. The boundary element method in conjunction with linear elastic fracture mechanics theories is used to predict arbitrarily shaped three dimensional fatigue crack trajectories in a spiral bevel pinion under moving load conditions. The predictions are validated by comparison to experimental results. The sensitivity of the predictions to variations in loading conditions and crack growth rate model parameters is explored. Critical areas that must be understood in greater detail prior to predicting more accurate crack trajectories and crack growth rates in three dimensions are identified.

Spievak, Lisa E.↗

NASA NTRS2001

Effect of Speed (Centrifugal Load) on Gear Crack Propagation Direction

The effect of rotational speed (centrifugal force) on gear crack propagation direction was explored. Gears were analyzed using finite element analysis and linear elastic fracture mechanics. The analysis was validated with crack propagation experiments performed in a spur gear fatigue rig. The effects of speed, rim thickness, and initial crack location on gear crack propagation direction were investigated. Crack paths from the finite element method correlated well with those deduced from gear experiments. For the test gear with a backup ratio (rim thickness divided by tooth height) of nib = 0.5, cracks initiating in the tooth fillet propagated to rim fractures when run at a speed of 10,000 rpm and became tooth fractures for speeds slower than 10,000 rpm for both the experiments and anal~ sis. From additional analysis, speed had little effect on crack propagation direction except when initial crack locations were near the tooth/rim fracture transition point for a given backup ratio. When at that point, higher speeds tended to promote rim fracture while lower speeds (or neglecting centrifugal force) produced tooth fractures.

Lewicki, David G.↗