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NASA NTRS1973

Stress intensity factors for long, deep surface flaws in plates under extensional fields

Using a singular solution for a part circular crack, a Taylor Series Correction Method (TSCM) was verified for extracting stress intensity factors from photoelastic data. Photoelastic experiments were then conducted on plates with part circular and flat bottomed cracks for flaw depth to thickness ratios of 0.25, 0.50 and 0.75 and for equivalent flaw depth to equivalent ellipse length values ranging from 0.066 to 0.319. Experimental results agreed well with the Smith theory but indicated that the use of the ''equivalent'' semi-elliptical flaw results was not valid for a/2c less than 0.20. Best overall agreement for the moderate (a/t approximately 0.5) to deep flaws (a/t approximatelly 0.75) and a/2c greater than 0.15 was found with a semi-empirical theory, when compared on the basis of equivalent flaw depth and area.

Harms, A. E.↗

NASA NTRS1974

Holographic and ultrasonic detection of bond flaws in aluminum panels reinforced with boron-epoxy

An experimental investigation was made of the application of holographic interferometry to the nondestructive detection of unbonded areas (flaws) in bonded panels. Flaw detection results were compared with results obtained with an ultrasonic flaw detector. Holography, with panel deformation accomplished by a reduction in ambient pressure, is less sensitive for flaws beneath 5 and 10 plies of boron-epoxy than the ultrasonic method, though it does have its operational advantages. A process for the manufacture of bonded panels which incorporate known unbonded areas was also developed. The unbonded areas were formed without the use of foreign materials, which makes the method suitable for the construction of reference standards for bonded panels whenever needed for the proper setup of ultrasonic flaw-detection instruments.

Platt, R. J., Jr.↗

NASA NTRS1974

Effects of proof loads and combined mode loadings on fracture and flaw growth characteristics of aerospace alloys

This experimental program was undertaken to determine the effects of (1) combined tensile and bending loadings, (2) combined tensile and shear loadings, and (3) proof overloads on fracture and flaw growth characteristics of aerospace alloys. Tests were performed on four alloys: 2219-T87 aluminum, 5Al-2.5Sn (ELl) titanium, 6Al-4V beta STA titanium and high strength 4340 steel. Tests were conducted in room air, gaseous nitrogen at -200F (144K), liquid nitrogen and liquid hydrogen. Flat center cracked and surface flawed specimens, cracked tube specimens, circumferentially notched round bar and surface flawed cylindrical specimens were tested. The three-dimensional photoelastic technique of stress freezing and slicing was used to determine stress intensity factors for surface flawed cylindrical specimens subjected to tension or torsion. Results showed that proof load/temperature histories used in the tests have a small beneficial effect or no effect on subsequent fracture strength and flaw growth rates.

Shah, R. C.↗

NASA NTRS1978

Crack extension from flaws in a brittle material subjected to compression

The mechanisms by which cracks extend from flaws in brittle materials subjected to compressive loads are presented. Although it is recognized that most geological materials are neither dense nor single-phase, this experimental study and analysis are restricted to single-phase, dense materials in order to provide a model amenable to analysis and experimental confirmation. The flaws which occur in dense, single-phase materials are divided into three types, each type having different characteristics of crack extension. Experimental studies of crack extension from flaws introduced into blocks of polymethylmethacrylate plastic are described. The studies show that crack extension from three dimensional flaws is more complex than two-dimensional theories predict. The extension of secondary cracks may result in more damage than that which would be predicted by considering only the primary crack extension treated by current theories. The importance of the dynamic behavior of flaws which stick and then suddenly slip is shown.

Adams, M.↗

NASA NTRS1986

Quantitative flaw characterization with scanning laser acoustic microscopy

Surface roughness and diffraction are two factors that have been observed to affect the accuracy of flaw characterization with scanning laser acoustic microscopy. In accuracies can arise when the surface of the test sample is acoustically rough. It is shown that, in this case, Snell's law is no longer valid for determining the direction of sound propagation within the sample. The relationship between the direction of sound propagation within the sample, the apparent flaw depth, and the sample's surface roughness is investigated. Diffraction effects can mask the acoustic images of minute flaws and make it difficult to establish their size, depth, and other characteristics. It is shown that for Fraunhofer diffraction conditions the acoustic image of a subsurface defect corresponds to a two-dimensional Fourier transform. Transforms based on simulated flaws are used to infer the size and shape of the actual flaw.

Generazio, E. R.↗

NASA NTRS1986

Quantitative flaw characterization with scanning laser acoustic microscopy

Surface roughness and diffraction are two factors that have been observed to affect the accuracy of flaw characterization with scanning laser acoustic microscopy. Inaccuracies can arise when the surface of the test sample is acoustically rough. It is shown that, in this case, Snell's law is no longer valid for determining the direction of sound propagation within the sample. The relationship between the direction of sound propagation within the sample, the apparent flaw depth, and the sample's surface roughness is investigated. Diffraction effects can mask the acoustic images of minute flaws and make it difficult to establish their size, depth, and other characteristics. It is shown that for Fraunhofer diffraction conditions the acoustic image of a subsurface defect corresponds to a two-dimensional Fourier transform. Transforms based on simulated flaws are used to infer the size and shape of the actual flaw.

Generazio, E. R.↗

NASA NTRS1990

Application of acoustic emission to flaw detection in engineering materials

Monitoring of structures under operating loads to provide an early warning of possible failure to locate flaws in test specimens subjected to uniaxial tensile loading is presented. Test specimens used are mild steel prismatic bars with small holes at different locations. When the test specimen is loaded, acoustic emission data are automatically collected by two acoustic transducers located at opposite sides of the hole and processed by an acoustic emission analyzer. The processed information yields the difference in arrival times at the transducers, which uniquely determines the flaw location. By using this technique, flaws were located to within 8 percent of their true location. The use of acoustic emission in linear location to locate a flaw in a material is demonstrated. It is concluded that this one-dimensional application could be extended to the general flaw location problem through triangulation.

Moslehy, F. A.↗

NASA NTRS1992

Application of elastic and elastic-plastic fracture mechanics methods to surface flaws

Fuel tanks that are a part of the External Tank assembly for the Space Shuttle are made of relatively thin 2219-T87 aluminum plate. These tanks contain about 917 m of fusion weld seam, all of which is nondestructively inspected for flaws and all those found are repaired. The tanks are subsequently proof-tested to a pressure that is sufficiently severe to cause weld metal yielding in a few local regions of the weld seam. The work undertaken in the present project was to develop a capability to predict flaw growth from undetected surface flaws that are assumed to be located in the highly stressed regions. The technical challenge was to develop R-curve prediction capability for surface cracks in specimens that contain the flaws of unusual sizes and shapes deemed to be of interest. The test techniques developed and the elastic-plastic analysis concepts adopted are presented. The flaws of interest were quite small surface cracks that were narrow-deep ellipses that served to exacerbate the technical difficulties involved.

Mccabe, Donald E.↗

NASA NTRS2007

Development of Natural Flaw Samples for Evaluating Nondestructive Testing Methods for Foam Thermal Protection Systems

Low density polyurethane foam has been an important insulation material for space launch vehicles for several decades. The potential for damage from foam breaking away from the NASA External Tank was not realized until the foam impacts on the Columbia Orbiter vehicle caused damage to its Leading Edge thermal protection systems (TPS). Development of improved inspection techniques on the foam TPS is necessary to prevent similar occurrences in the future. Foamed panels with drilled holes for volumetric flaws and Teflon inserts to simulate debonded conditions have been used to evaluate and calibrate nondestructive testing (NDT) methods. Unfortunately the symmetric edges and dissimilar materials used in the preparation of these simulated flaws provide an artificially large signal while very little signal is generated from the actual defects themselves. In other words, the same signal are not generated from the artificial defects in the foam test panels as produced when inspecting natural defect in the ET foam TPS. A project to create more realistic voids similar to what actually occurs during manufacturing operations was began in order to improve detection of critical voids during inspections. This presentation describes approaches taken to create more natural voids in foam TPS in order to provide a more realistic evaluation of what the NDT methods can detect. These flaw creation techniques were developed with both sprayed foam and poured foam used for insulation on the External Tank. Test panels with simulated defects have been used to evaluate NDT methods for the inspection of the External Tank. A comparison of images between natural flaws and machined flaws generated from backscatter x-ray radiography, x-ray laminography, terahertz imaging and millimeter wave imaging show significant differences in identifying defect regions.

Workman, Gary L.↗

NASA NTRS2015

Simulating the X-Ray Image Contrast to Set-Up Techniques with Desired Flaw Detectability

The paper provides simulation data of previous work by the author in developing a model for estimating detectability of crack-like flaws in radiography. The methodology is being developed to help in implementation of NASA Special x-ray radiography qualification, but is generically applicable to radiography. The paper describes a method for characterizing X-ray detector resolution for crack detection. Applicability of ASTM E 2737 resolution requirements to the model are also discussed. The paper describes a model for simulating the detector resolution. A computer calculator application, discussed here, also performs predicted contrast and signal-to-noise ratio calculations. Results of various simulation runs in calculating x-ray flaw size parameter and image contrast for varying input parameters such as crack depth, crack width, part thickness, x-ray angle, part-to-detector distance, part-to-source distance, source sizes, and detector sensitivity and resolution are given as 3D surfaces. These results demonstrate effect of the input parameters on the flaw size parameter and the simulated image contrast of the crack. These simulations demonstrate utility of the flaw size parameter model in setting up x-ray techniques that provide desired flaw detectability in radiography. The method is applicable to film radiography, computed radiography, and digital radiography.

Koshti, Ajay M.↗

NASA NTRS1973

Fracture characteristics of structural aerospace alloys containing deep surface flaws

Conditions controlling the growth and fracture of deep surface flaws in aerospace alloys were investigated. Static fracture tests were performed on 7075-T651 and 2219-T87 aluminum, and 6Ai-4V STA titanium . Cyclic flaw growth tests were performed on the two latter alloys, and sustain load tests were performed on the titanium alloy. Both the cyclic and the sustain load tests were performed with and without a prior proof overload cycle to investigate possible growth retardation effects. Variables included in all test series were thickness, flaw depth-to-thickness ratio, and flaw shape. Results were analyzed and compared with previously developed data to determine the limits of applicability of available modified linear elastic fracture solutions.

Masters, J. N.↗

NASA NTRS1973

Combined effects of weld-induced residual stresses and flaws on the fracture strength of Ti-5Al-2.5Sn

The combined effects of weld-induced residual stresses and flaws on fracture strength were experimentally evaluated by testing Ti-5Al-2.5Sn surface flawed specimens at -320F (-195C) in liquid nitrogen. Flaws were located in weld metal with crack planes either parallel to or perpendicular to gas tungsten arc weld centerlines, and in base metal with the crack plane perpendicular to the rolling direction. Tests were conducted using two different flaw sizes to effect fracture stresses at two different levels including one level either at or near, and one level well below the tensile yield strength. Three different residual stress levels were generated, measured, and tested. Results were evaluated using modified linear elastic fracture mechanics theory.

Hall, L. R.↗

NASA NTRS1975

Effect of thermal profile on cyclic flaw growth in aluminum

Surface flawed and single edge notch tension specimens of 2219-T851 and -T87 aluminum were tested to determine static fracture characteristics and base line (constant amplitude, constant temperature) cyclic flaw growth behavior. Subsequent testing was then conducted in which flawed specimens were subjected to a thermal profile in which the applied stress was varied simultaneously with the temperature. The profile used represents a simplified space shuttle orbiter load/temperature flight cycle. Test temperatures included the range from 144K (-200 F) up to 450K (350 F). The measured flaw growth rates obtained from the thermal profile tests were then compared with rates predicted by assuming linear cumulative damage of base line rates.

Engstrom, W. L.↗

NASA NTRS1975

The detection of tightly closed flaws by nondestructive testing (NDT) methods

Liquid penetrant, ultrasonic, eddy current and X-radiographic techniques were optimized and applied to the evaluation of 2219-T87 aluminum alloy test specimens in integrally stiffened panel, and weld panel configurations. Fatigue cracks in integrally stiffened panels, lack-of-fusion in weld panels, and fatigue cracks in weld panels were the flaw types used for evaluation. A 2319 aluminum alloy weld filler rod was used for all welding to produce the test specimens. Forty seven integrally stiffened panels containing a total of 146 fatigue cracks, ninety three lack-of-penetration (LOP) specimens containing a total of 239 LOP flaws, and one-hundred seventeen welded specimens containing a total of 293 fatigue cracks were evaluated. Nondestructive test detection reliability enhancement was evaluated during separate inspection sequences in the specimens in the 'as-machined or as-welded', post etched and post proof loaded conditions. Results of the nondestructive test evaluations were compared to the actual flaw size obtained by measurement of the fracture specimens after completing all inspection sequences. Inspection data were then analyzed to provide a statistical basis for determining the flaw detection reliability.

Rummel, W. D.↗

NASA NTRS1976

Ductile fracture of cylindrical vessels containing a large flaw

The fracture process in pressurized cylindrical vessels containing a relatively large flaw is considered. The flaw is assumed to be a part-through or through meridional crack. The flaw geometry, the yield behavior of the material, and the internal pressure are assumed to be such that in the neighborhood of the flaw the cylinder wall undergoes large-scale plastic deformations. Thus, the problem falls outside the range of applicability of conventional brittle fracture theories. To study the problem, plasticity considerations are introduced into the shell theory through the assumptions of fully-yielded net ligaments using a plastic strip model. Then a ductile fracture criterion is developed which is based on the concept of net ligament plastic instability. A limited verification is attempted by comparing the theoretical predictions with some existing experimental results.

Erdogan, F.↗

NASA NTRS1979

Influence of flaw geometries on hole-crack stress intensities

The paper deals with a frozen-stress photoelastic study of a class of flaw shapes where the ratio of the hole diameter to plate thickness is approximately unity. The study was carried out by a technique developed for estimating stress intensity factor variations along the border of flaws in three-dimensional problems. The results show that for deep flaws, the flaw shapes are not simple and the flow growth is not self-similar. The implications of this effect are discussed.

Smith, C. W.↗

NASA NTRS1987

Surface flaw reliability analysis of ceramic components with the SCARE finite element postprocessor program

The SCARE (Structural Ceramics Analysis and Reliability Evaluation) computer program on statistical fast fracture reliability analysis with quadratic elements for volume distributed imperfections is enhanced to include the use of linear finite elements and the capability of designing against concurrent surface flaw induced ceramic component failure. The SCARE code is presently coupled as a postprocessor to the MSC/NASTRAN general purpose, finite element analysis program. The improved version now includes the Weibull and Batdorf statistical failure theories for both surface and volume flaw based reliability analysis. The program uses the two-parameter Weibull fracture strength cumulative failure probability distribution model with the principle of independent action for poly-axial stress states, and Batdorf's shear-sensitive as well as shear-insensitive statistical theories. The shear-sensitive surface crack configurations include the Griffith crack and Griffith notch geometries, using the total critical coplanar strain energy release rate criterion to predict mixed-mode fracture. Weibull material parameters based on both surface and volume flaw induced fracture can also be calculated from modulus of rupture bar tests, using the least squares method with known specimen geometry and grouped fracture data. The statistical fast fracture theories for surface flaw induced failure, along with selected input and output formats and options, are summarized. An example problem to demonstrate various features of the program is included.

Gyekenyesi, John P.↗

NASA NTRS1987

Surface flaw reliability analysis of ceramic components with the SCARE finite element postprocessor program

Gyekenyesi, J. P.↗