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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

From S-N to the Paris Law with a New Mixed-Mode Cohesive Fatigue Model

The relationship between fatigue life and fatigue crack propagation rate is explored with a new cohesive damage model. The parameters of the model are obtained from idealizations of S-N diagrams used in engineering design. The model is based on the hypothesis that both stable tearing damage and damage due to cyclic loading are representations of a density of microcracks and, therefore, a single damage variable can describe the state of damage. This assumption implies that the quasi-static cohesive law that describes tearing is also the envelope of the fatigue damage. Fatigue damage within the cohesive envelope is assumed to accumulate at a rate that depends on the displacement jumps. The fatigue model was implemented as a UMAT subroutine for Abaqus cohesive elements by adding fatigue damage accumulation to a cohesive model based on the Turon mixed-mode cohesive laws. The analyses were conducted using a simplified cyclic loading procedure in which the maximum applied load is kept constant and the computational expense of cycling the load is avoided. The predicted propagation rates in mode I and mixed mode were compared to experimental results for IM7/8552 graphite/epoxy tape. Several aspects of the results were investigated, including the effect of R-curves, the stress ratio R, and the difference between displacement control and force control.

Davila, Carlos G.↗
NASA NTRS2018

A Cohesive Fatigue Model Based on the S-N Diagram

The relationship between fatigue life and fatigue crack propagation rate is explored with a new cohesive damage model. The parameters of the model are obtained from idealizations of S-N diagrams used in engineering design. The model is based on the hypothesis that both stable tearing damage and damage due to cyclic loading are representations of a density of microcracks and, therefore, a single damage variable can describe the state of damage. This assumption implies that the quasi-static cohesive law that describes tearing is also the envelope of the fatigue damage. Fatigue damage within the cohesive envelope is assumed to accumulate at a rate that depends on the displacement jumps. The fatigue model was implemented as a UMAT subroutine for Abaqus cohesive elements by adding fatigue damage accumulation to a cohesive model based on the Turon quasi-static cohesive law. The analyses were conducted using a simplified cyclic loading procedure in which the maximum applied load is kept constant and the computational expense of cycling the load is avoided. The predicted propagation rates for a double cantilever beam (DCB) specimen were compared to experimental results for IM7/8552 graphite/epoxy tape.

Dávila, Carlos G.↗
DOE OSTI2021

Fatigue behavior of fine-grained magnesium under tension-tension loading at 0 °C

Here, this study investigated low-temperature fatigue behavior of fine-grained magnesium through tension–tension fatigue testing at the temperature of 0 °C. The applied stress profiles of fatigue testing were selected to cover a wide range of loading conditions including low, medium, and high loading stresses. Even when the maximum applied stress of fatigue testing was as high as 88% of the ultimate tensile strength of the material, the corresponding fatigue life was long, i.e., 3973 cycles. Deformation accumulation per loading cycle reduced with the progression of fatigue testing for all studied loading conditions. Fatigue life analyses were performed using both Smith-Watson-Topper (SWT) model and Jahed-Varvani energy-based (JV) model. The fatigue life predictions through both models agree well with the experimental data.

36 MATERIALS SCIENCE↗
NASA NTRS1981

Effects of ultra-clean and centrifugal filtration on rolling-element bearing life

Fatigue tests were conducted on groups of 65-mm bore diameter deep-groove ball bearings in a MIL-L-23699 lubricant under two levels of filtration to determine the upper limit in bearing life under the strictest possible lubricant cleanliness conditions. Bearing fatigue lives, surface distress and weight loss were compared to previous bearing fatigue tests in contaminated and noncontaminated oil filters having absolute removal ratings of 3, 30, 49, and 105 microns, with lubricant and sump temperatures maintained at 347 K. Ultra clean lubrication was found to produce bearing fatigue lives that were approximately twice that obtained in previous tests with contaminated oil using 3 micron absolute filtration. It was also observed that the centrifugal oil filter has the same effectiveness as a 30 micron absolute filter in preventing surface damage.

Loewenthal, S. H.↗
NASA NTRS1990

Probabilistic fatigue methodology for six nines reliability

Fleet readiness and flight safety strongly depend on the degree of reliability that can be designed into rotorcraft flight critical components. The current U.S. Army fatigue life specification for new rotorcraft is the so-called six nines reliability, or a probability of failure of one in a million. The progress of a round robin which was established by the American Helicopter Society (AHS) Subcommittee for Fatigue and Damage Tolerance is reviewed to investigate reliability-based fatigue methodology. The participants in this cooperative effort are in the U.S. Army Aviation Systems Command (AVSCOM) and the rotorcraft industry. One phase of the joint activity examined fatigue reliability under uniquely defined conditions for which only one answer was correct. The other phases were set up to learn how the different industry methods in defining fatigue strength affected the mean fatigue life and reliability calculations. Hence, constant amplitude and spectrum fatigue test data were provided so that each participant could perform their standard fatigue life analysis. As a result of this round robin, the probabilistic logic which includes both fatigue strength and spectrum loading variability in developing a consistant reliability analysis was established. In this first study, the reliability analysis was limited to the linear cumulative damage approach. However, it is expected that superior fatigue life prediction methods will ultimately be developed through this open AHS forum. To that end, these preliminary results were useful in identifying some topics for additional study.

Everett, R. A., Jr.↗
NASA NTRS1975

Life analysis of helical gear sets using Lundberg-Palmgren theory

A mathematical model is developed for surface fatigue life of helical gears. The expected fatigue life of a pinion, gear, or gear set may be calculated from the model. An equation for the dynamic capacity of a gear set was also derived. Dynamic capacity is the transmitted tangential load which gives a 90 percent probability of survival of the gear set for one million pinion revolutions. The equations, when simplified by setting the helix angle to zero, reduce to the results which were previously developed for spur gears. A sample calculation is given which illustrates the use of the new fatigue life model.

Coy, J. J.↗
NASA NTRS2024

Flexural Fatigue Testing and Qualification of Hybrid PAN-pitch Composite Materials with High Through-Thickness Thermal Conductivity

Carbon-fiber-reinforced polymers (CFRPs) considered for motor components within future electric vertical takeoff and landing (eVTOL) vehicles require not only a high strength-to-weight ratio but also a high through-thickness thermal conductivity (TC) to dissipate heat. Previously, CFRPs incorporating pitch CF interleaves demonstrated an increased through-thickness TC relative to the baseline composite, but the effect on flexural fatigue life was not evaluated. For this work, T700S/TC275–1 braided carbon fiber/epoxy prepreg baseline (no interleave), YSH–60A pitch interleave, and YS–80A pitch interleave configurations were tested for fatigue life. A combination of ASTM International Standards D7264 and D3479 were used to develop a reliable testing method. An Instron® (Illinois Tool Works Inc.) 8501 servohydraulic system with a fatigue test fixture was set up with a 16:1 span:thickness ratio, load ratio R set to 0.1, and frequency of 4 Hz. High-cycle fatigue testing was completed, and it was found that YSH–60A interleave performed slightly better than YS–80A below 100,000 cycles but showed no differences above 100,000 cycles. In all cases, the baseline CFRP had superior fatigue life performance both in terms of stress handled and total cycles to failure. These fatigue testing data will inform future use of hybrid CFRP materials by highlighting the tradeoff between increased through-thickness TC and fatigue life. Testing guidelines, equipment, and parameters for static and fatigue tests were successfully outlined for CFRPs.

composites↗
NASA NTRS1984

Crack tip field and fatigue crack growth in general yielding and low cycle fatigue

Fatigue life consists of crack nucleation and crack propagation periods. Fatigue crack nucleation period is shorter relative to the propagation period at higher stresses. Crack nucleation period of low cycle fatigue might even be shortened by material and fabrication defects and by environmental attack. In these cases, fatigue life is largely crack propagation period. The characteristic crack tip field was studied by the finite element method, and the crack tip field is related to the far field parameters: the deformation work density, and the product of applied stress and applied strain. The cyclic carck growth rates in specimens in general yielding as measured by Solomon are analyzed in terms of J-integral. A generalized crack behavior in terms of delta is developed. The relations between J and the far field parameters and the relation for the general cyclic crack growth behavior are used to analyze fatigue lives of specimens under general-yielding cyclic-load. Fatigue life is related to the applied stress and strain ranges, the deformation work density, crack nucleus size, fracture toughness, fatigue crack growth threshold, Young's modulus, and the cyclic yield stress and strain. The fatigue lives of two aluminum alloys correlate well with the deformation work density as depicted by the derived theory. The general relation is reduced to Coffin-Manson low cycle fatigue law in the high strain region.

Minzhong, Z.↗
NASA NTRS1995

Failure models for textile composites

The goals of this investigation were to: (1) identify mechanisms of failure and determine how the architecture of reinforcing fibers in 3D woven composites controlled stiffness, strength, strain to failure, work of fracture, notch sensitivity, and fatigue life; and (2) to model composite stiffness, strength, and fatigue life. A total of 11 different angle and orthogonal interlock woven composites were examined. Composite properties depended on the weave architecture, the tow size, and the spatial distributions and strength of geometrical flaws. Simple models were developed for elastic properties, strength, and fatigue life. A more complicated stochastic model, called the 'Binary Model,' was developed for damage tolerance and ultimate failure. These 3D woven composites possessed an extraordinary combination of strength, damage tolerance, and notch insensitivity.

Cox, Brian↗
NASA NTRS1991

Isothermal fatigue behavior of a (90)(sub 8) SiC/Ti-15-3 composite at 426 C

The transverse fatigue behavior of a unidirectional, SiC/Ti-15-3 composite (35 v/o SiC, (90)(sub 8)) was evaluated at 426 C. The fatigue behavior of the composite along the fiber direction (0)(sub 8) and of unreinforced Ti-15-3 alloy were also studied for comparison purposes. The (90)(sub 8) composite fatigue life was much shorter then (0)(sub 8) life. Further, (90)(sub 8) fatigue life was also found to be far lower than that of the unreinforced Ti-15-3 alloys. A simple one-dimensional model for (90)(sub 8) fatigue behavior indicated that the short life of the composite in this orientation resulted, in large part, from weak fiber-matrix bond strength. This conclusion was supported by fractographic evidence showing numerous initiation sites along the fiber-matrix interfaces.

Gayda, John↗
NASA NTRS1990

A transient plasticity study and low cycle fatigue analysis of the Space Station Freedom photovoltaic solar array blanket

The Space Station Freedom photovoltaic solar array blanket assembly is comprised of several layers of materials having dissimilar elastic, thermal, and mechanical properties. The operating temperature of the solar array, which ranges from -75 to +60 C, along with the material incompatibility of the blanket assembly components combine to cause an elastic-plastic stress in the weld points of the assembly. The weld points are secondary structures in nature, merely serving as electrical junctions for gathering the current. The thermal mechanical loading of the blanket assembly operating in low earth orbit continually changes throughout each 90 min orbit, which raises the possibility of fatigue induced failure. A series of structural analyses were performed in an attempt to predict the fatigue life of the solar cell in the Space Station Freedom photovoltaic array blanket. A nonlinear elastic-plastic MSC/NASTRAN analysis followed by a fatigue calculation indicated a fatigue life of 92,000 to 160,000 cycles for the solar cell weld tabs. Additional analyses predict a permanent buckling phenomenon in the copper interconnect after the first loading cycle. This should reduce or eliminate the pulling of the copper interconnect on the joint where it is welded to the silicon solar cell. It is concluded that the actual fatigue life of the solar array blanket assembly should be significantly higher than the calculated 92,000 cycles, and thus the program requirement of 87,500 cycles (orbits) will be met. Another important conclusion that can be drawn from the overall analysis is that, the strain results obtained from the MSC/NASTRAN nonlinear module are accurate to use for low-cycle fatigue analysis, since both thermal cycle testing of solar cells and analysis have shown higher fatigue life than the minimum program requirement of 87,500 cycles.

Armand, Sasan C.↗
NASA NTRS1988

Grain boundary oxidation and an analysis of the effects of oxidation on fatigue crack nucleation life

The effects of preoxidation on subsequent fatigue life were studied. Surface oxidation and grain boundary oxidation of a nickel-base superalloy (TAZ-8A) were studied at 600 to 1000 C for 10 to 1000 hours in air. Surface oxides were identified and the kinetics of surface oxidation was discussed. Grain boundary oxide penetration and morphology were studied. Pancake type grain boundary oxide penetrates deeper and its size is larger, therefore, it is more detrimental to fatigue life than cone-type grain boundary oxide. Oxide penetration depth, a (sub m), is related to oxidation temperature, T, and exposure time, t, by an empirical relation of the Arrhenius type. Effects of T and t on statistical variation of a (sub m) were analyzed according to the Weibull distribution function. Once the oxide is cracked, it serves as a fatigue crack nucleus. Statistical variation of the remaining fatigue life, after the formation of an oxide crack of a critical length, is related directly to the statistical variation of grain boundary oxide penetration depth.

Oshida, Y.↗
NASA NTRS2009

Interference-Fit Life Factors for Roller Bearings

The effect of hoop stresses in reducing cylindrical roller bearing fatigue life was determined for various classes of inner-ring interference fit. Calculations were performed for up to 7 fit classes for each of 10 bearing sizes. The hoop stresses were superimposed on the Hertzian principal stresses created by the applied radial load to calculate roller bearing fatigue life. A method was developed through a series of equations to calculate the life reduction for cylindrical roller bearings. All calculated lives are for zero initial internal clearance. Any reduction in bearing clearance due to interference fit would be compensated by increasing the initial (unmounted) clearance. Results are presented as tables and charts of life factors for bearings with light, moderate, and heavy loads and interference fits ranging from extremely light to extremely heavy for bearing accuracy class RBEC-5 (ISO class 5). Interference fits on the inner ring of a cylindrical roller bearing can significantly reduce bearing fatigue life. In general, life factors are smaller (lower life) for bearings running under light load where the unfactored life is highest. The various bearing series within a particular bore size had almost identical interference-fit life factors for a particular fit. The tightest fit at the high end of the tolerance band produces a life factor of approximately 0.40 for an inner-race maximum Hertz stress of 1200 MPa (175 ksi) and a life factor of 0.60 for an inner-race maximum Hertz stress of 2200 MPa (320 ksi). Interference fits also impact the maximum Hertz stress-life relation.

Oswald, Fred B.↗
NASA NTRS2008

Interference Fit Life Factors for Roller Bearings

The effect of hoop stresses in reducing cylindrical roller bearing fatigue life was determined for various classes of inner ring interference fit. Calculations were performed for up to seven interference fit classes for each of ten bearing sizes. Each fit was taken at tightest, average and loosest values within the fit class for RBEC-5 tolerance, thus requiring 486 separate analyses. The hoop stresses were superimposed on the Hertzian principal stresses created by the applied radial load to calculate roller bearing fatigue life. The method was developed through a series of equations to calculate the life reduction for cylindrical roller bearings based on interference fit. All calculated lives are for zero initial bearing internal clearance. Any reduction in bearing clearance due to interference fit was compensated by increasing the initial (unmounted) clearance. Results are presented as tables and charts of life factors for bearings with light, moderate and heavy loads and interference fits ranging from extremely light to extremely heavy and for bearing accuracy class RBEC 5 (ISO class 5). Interference fits on the inner bearing ring of a cylindrical roller bearing can significantly reduce bearing fatigue life. In general, life factors are smaller (lower life) for bearings running under light load where the unfactored life is highest. The various bearing series within a particular bore size had almost identical interference fit life factors for a particular fit. The tightest fit at the high end of the RBEC-5 tolerance band defined in ANSI/ABMA shaft fit tables produces a life factor of approximately 0.40 for an inner-race maximum Hertz stress of 1200 MPa (175 ksi) and a life factor of 0.60 for an inner-race maximum Hertz stress of 2200 MPa (320 ksi). Interference fits also impact the maximum Hertz stress-life relation.

Oswald, Fred B.↗
NASA NTRS2001

Ceramic Inclusions in Powder Metallurgy Disk Alloys: Characterization and Modeling

Powder metallurgy alloys are increasingly used in gas turbine engines, especially in turbine disk applications. Although powder metallurgy materials have many advantages over conventionally cast and wrought alloys (higher strength, higher temperature capability, etc.), they suffer from the rare occurrence of ceramic defects (inclusions) that are inherent to the powder atomization process. These inclusions can have a potentially large detrimental effect on the durability of individual components. An inclusion in a high stress location can act as a site for premature crack initiation and thereby considerably reduce the fatigue life. Because these inclusions are exceedingly rare, they typically do not reveal themselves in the process of characterizing the material for a particular application (the cumulative volume of the test bars in a fatigue life characterization is typically on the order of a single actual component). Ceramic inclusions have, however, been found to be the root cause of a number of catastrophic engine failures. To investigate the effect of these inclusions in detail, we have undertaken a study where known populations of ceramic particles, whose composition and morphology are designed to mimic the "natural" inclusions, are added to the precursor powder. Surface-connected inclusions have been found to have a particularly large detrimental effect on fatigue life; therefore, the quantity of ceramic "seeds" added is calculated to ensure that a minimum number will intersect the surface of the fatigue test bars. Because the ceramic inclusions are irregularly shaped and have a tendency to break up in the process of extrusion and forging, a method of calculating the probability of occurrence and expected intercepted surface area was needed. We have developed a Monte Carlo simulation to determine the distributions of these parameters and have verified the simulated results with observations of ceramic inclusions found in macroscopic slices from extrusions and forgings. Fatigue specimens have been machined from Udimet 720 (a powder metallurgy superalloy) forgings, to determine the effects of the inclusions on fatigue life. The ultimate goal of this study will be to use probabilistic methods to determine the reliability detriment that can be attributed to these ceramic inclusions. This work has been supported by the Ultra Safe and Ultra- Efficient Engine Technologies programs.

Bonacuse, Peter J.↗
NASA NTRS2010

Probabilistic Simulation for Combined Cycle Fatigue in Composites

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multifactor interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Chamis, Christos C.↗
NASA NTRS1996

Effect of Cyclic Thermo-Mechanical Loads on Fatigue Reliability in Polymer Matrix Composites

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multi-factor interaction relationship developed at NASA Lewis Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability- based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)(sub s) graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Shah, A. R.↗
NASA NTRS2010

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

A methodology to compute probabilistically-combined thermo-mechanical fatigue life of polymer matrix laminated composites has been developed and is demonstrated. Matrix degradation effects caused by long-term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress-dependent multifactor-interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability-integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/-45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical-cyclic loads and low thermal-cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical-cyclic loads and high thermal-cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Chamis, Christos C.↗