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Evaluation of RSRM case hardware fretting concerns

Fretting corrosion was first noted on Shuttle flight STS-26. This flight was the first usage of the Redesigned Solid Rocket Motor (RSRM). The occurrence of fretting has since been observed on both the field and factory joints of the RSRM. Fretting is a form of corrosion that occurs at the interface between contacting, highly loaded, metal surfaces when exposed to slight relative vibratory motions. The engineering effort performed to evaluate the effect of fretting on the RSRM case hardware is summarized. Based on the results of this evaluation, several conclusions were made concerning flight safety. Also, recommendations were made concerning trending the effects of multiple generations of fretting damage.

Swauger, Thomas R.

Preliminary Study on Fatigue Strengths of Fretted Ti-48Al-2Cr-2Nb

The fatigue behavior (stress-life curve) of gamma titanium aluminide (Ti-48Al-2Cr-2Nb, atomic percent) was examined by conducting two tests: first, a fretting wear test with a fatigue specimen in contact with a typical nickel-based superalloy contact pad in air at temperatures of 296 and 823 K and second, a high-cycle fatigue test of the prefretted Ti-48Al-2Cr-2Nb fatigue specimen at 923 K. Reference high-cycle fatigue tests were also conducted with unfretted Ti-48Al-2Cr-2Nb specimens at 923 K. All Ti-48Al-2Cr-2Nb fatigue specimens were machined from cast slabs. The results indicate that the stress-life results for the fretted Ti-48Al-2Cr-2Nb specimens exhibited a behavior similar to those of the unfretted Ti-48Al-2Cr-2Nb specimens. The values of maximum stress and life for the fretted specimens were almost the same as those for the unfretted specimens. The resultant stress-life curve for the unfretted fatigue specimens was very flat. The flat appearance in the stress-life curve of the unfretted specimens is attributed to the presence of a high density of casting pores. The fatigue strengths of both the fretted and unfretted specimens can be significantly affected by the presence of this porosity, which can decrease the fatigue life of Ti-48Al-2Cr-2Nb. The presence of the porosity made discerning the effect of fretting damage on fatigue strength and life of the specimens difficult.

Miyoshi, Kazuhisa

FRET-Aptamer Assays for Bone Marker Assessment, C-Telopeptide, Creatinine, and Vitamin D

Astronauts lose 1.0 to 1.5% of their bone mass per month on long-duration spaceflights. NASA wishes to monitor the bone loss onboard spacecraft to develop nutritional and exercise countermeasures, and make adjustments during long space missions. On Earth, the same technology could be used to monitor osteoporosis and its therapy. Aptamers bind to targets against which they are developed, much like antibodies. However, aptamers do not require animal hosts or cell culture and are therefore easier, faster, and less expensive to produce. In addition, aptamers sometimes exhibit greater affinity and specificity vs. comparable antibodies. In this work, fluorescent dyes and quenchers were added to the aptamers to enable pushbutton, one-step, bind-and-detect fluorescence resonance energy transfer (FRET) assays or tests that can be freeze-dried, rehydrated with body fluids, and used to quantitate bone loss of vitamin D levels with a handheld fluorometer in the spacecraft environment. This work generated specific, rapid, one-step FRET assays for the bone loss marker C-telopeptide (CTx) when extracted from urine, creatinine from urine, and vitamin D congeners in diluted serum. The assays were quantified in nanograms/mL using a handheld fluorometer connected to a laptop computer to convert the raw fluorescence values into concentrations of each analyte according to linear standard curves. DNA aptamers were selected and amplified for several rounds against a 26- amino acid form of CTx, creatinine, and vitamin D. The commonalities between loop structures were studied, and several common loop structures were converted into aptamer beacons with a fluorophore and quencher on each end. In theory, when the aptamer beacon binds its cognate target (CTx bone peptide, creatinine, or vitamin D), it is forced open and no longer quenched, so it gives off fluorescent light (when excited) in proportion to the amount of target present in a sample. This proportional increase in fluorescence is called a "lights on" FRET response. The vitamin D aptamer beacon gives a "lights off" or inversely proportional fluorescence response to the amount of vitamin D present in diluted serum. These FRET-aptamer assays are rapid (<30 minutes), sensitive (low ng/mL detection limits), and quite easy to carry out (add sample, mix, and detect in the handheld reader). Benefits include the speed of the assays as well as the small amount of space taken up by the handheld reader and cuvette assays. The aptamer DNA sequences represent novel additional features of the existing (patent-pending) FRET-aptamer assay platform.

Bruno, John G.

From Natural Language Requirements to the Verification of Programmable Logic Controllers: Integrating FRET into PLCverif

PLCverif is an actively developed project at CERN, enabling the formal verification of Programmable Logic Controller (PLC) programs in critical systems. In this paper, we present our work on improving the formal requirements specification experience in PLCverif through the use of natural language. To this end, we integrate NASA’s FRET, a formal requirement elicitation and authoring tool, into PLCverif. FRET is used to specify formal requirements in structured natural language, which automatically translates into temporal logic formulae. FRET’s output is then directly used by PLCverif for verification purposes. We discuss practical challenges that PLCverif users face when authoring requirements and the FRET features that help alleviate these problems. We present the new requirement formalization workflow and report our experience using it on two critical CERN case studies.

FRET

Preliminary Investigation of Fretting

An experimental investigation, using microscopic observation and color motion photomicrographs of the action, was conducted to determine the cause of fretting. Glass and other noncorrosive materials, as well as metals, were used as specimens. A very simple apparatus vibrated convex surfaces in contact with stationary flat surfaces at frequencies of 120 cycles or less than one cycle per second, an amplitude of 0.001 inch, and a load of 0.2 pound. The observations and analysis led to the conclusions that fretting was initiated by the loosening, due to the inherent adhesive forces, of finely divided and apparently virgin material, and that its initiation is independent of vibratory motion or high sliding speeds. The fretting of platinum, glass, quartz, ruby, and mica relegated the role of oxidation as a cause to that of a secondary factor. Fretting occurred to clean nonmetals and metals readily, and glass microscope slides and steel balls provide excellent method for visual studies. Video run time 9:54, color and sound (mp4). Available for download for best viewing. Document indicated in video is related in the repository and can also be downloaded for use at https://ntrs.nasa.gov/citations/19930083206.

fretting

From Natural Language Requirements to the Verification of Programmable Logic Controllers: Integrating FRET into PLCverif

PLCverif is an actively developed project at CERN, enabling the formal verification of Programmable Logic Controller (PLC) programs in critical systems. In this paper, we present our work on improving the formal requirements specification experience in PLCverif through the use of natural language. To this end, we integrate NASA’s FRET, a formal requirement elicitation and authoring tool, into PLCverif. FRET is used to specify formal requirements in structured natural language, which automatically translates into temporal logic formulae. FRET’s output is then directly used by PLCverif for verification purposes. We discuss practical challenges that PLCverif users face when authoring requirements and the FRET features that help alleviate these problems. We present the new requirement formalization workflow and report our experience using it on two critical CERN case studies.

FRET

Fretting wear in titanium, Monel-400, and cobalt 25-percent-molybdenum using scanning electron microscopy

Damage scar volume measurements taken from like metal fretting pairs combined with scanning electron microscopy observations showed that three sequentially operating mechanisms result in the fretting of titanium, Monel-400, and cobalt - 25-percent molybdenum. Initially, adhesion and plastic deformation of the surface played an important role. This was followed after a few hundred cycles by a fatigue mechanism which produced spall-like pits in the damage scar. Finally, a combination of oxidation and abrasion by debris particles became most significant. Damage scar measurements made on several elemental metals after 600,000 fretting cycles suggested that the ratio of oxide hardness to metal hardness was a measure of the susceptibility of a metal to progressive damage by fretting.

Bill, R. C.

Study of fretting wear in titanium, Monel-400, and cobalt-25 percent molybdenum using scanning electron microscopy.

Damage scar volume measurements taken from like metal fretting pairs, combined with scanning electron microscopy observations, showed that three sequentially operating mechanisms result in the fretting of titanium, Monel-400, and cobalt-25% molybdenum. Initially, adhesion and plastic deformation on the surface played an important role. This was followed after a few hundred cycles by a fatigue mechanism, producing spall-like pits in the damage scar. Finally, an oxidation-related mechanism became most significant. Damage scar measurements made on several elemental metals after 600,000 fretting cycles suggested that the ratio of oxide hardness to metal hardness was a measure of the susceptibility of a metal to progressive damage by fretting.

Bill, R. C.

Fretting in aircraft turbine engines

The problem of fretting in aircraft turbine engines is discussed. Critical fretting can occur on fan, compressor, and turbine blade mountings, as well as on splines, rolling element bearing races, and secondary sealing elements of face type seals. Structural fatigue failures have been shown to occur at fretted areas on component parts. Methods used by designers to reduce the effects of fretting are given.

Johnson, R. L.

Fretting in aircraft turbine engines

Fretting usually produces both polished and pitted areas. Fretting occurs in connection with the relative motion between contacting surface elements. Particular attention is given to fretting in seals, splines, fans, compressors, and turbine blades. Recommended approaches to mitigate fretting problems include a reduction of the adhesion between two surfaces. Approaches for doing this may include the development of alloys which spontaneously generate a self-healing surface film, different in composition from the bulk alloy. Other fundamental adhesion studies have shown that surface crystal structure and crystallographic orientation significantly affect the adhesion properties of alloys.

Johnson, R. L.

Review of factors that influence fretting wear

An assessment is made of presently obtained as well as published results in order to characterize the effects of contact conditions, environmental conditions, and material properties and behavior on fretting wear. The importance of material properties is discussed on the basis of interaction with other factors during fretting. While the isolated effect of contact load, fretting amplitude, temperature and atmosphere have been well explored, especially for the case mild steel, a deficiency is noted in studies of the effects of contact geometry and relative humidity, as well as the interaction of various fretting parameters.

Bill, R. C.

Effect of humidity on fretting wear of several pure metals

Fretting wear experiments with several pure metals were conducted in air at various relative humidity levels. The materials used were iron, aluminum, copper, silver, chromium, titanium, and nickel. Each pure metal had a maximum fretting wear volume at a specific humidity level RH sub max that was not dependent on mechanical factors such as contact load, fretting amplitude, and frequency in the ranges studied. The weight loss due to fretting wear at RH sub max for each pure metal decreased with increasing heat of oxygen adsorption on the metal, indicating that adhesive wear dominated at RH sub max.

Goto, H.

Evaluation of Ti-48Al-2Cr-2Nb Under Fretting Conditions

The fretting behavior of Ti-48Al-2Cr-2Nb (y-TiAl) in contact with the nickel-base superalloy 718 was examined in air at temperatures from 296 to 823 K (23 to 550 C). The interfacial adhesive bonds between Ti-48Al-2Cr-2Nb and superalloy 718 were generally stronger than the cohesive bonds within Ti-48Al-2Cr-2Nb. The failed Ti-48Al-2Cr-2Nb debris subsequently transferred to the superalloy 718. In reference experiments conducted with Ti-6Al-4V against superalloy 718 under identical fretting conditions, the degree of transfer was greater for Ti-6A1-4V than for Ti-48Al-2Cr-2Nb. Wear of Ti-48Al-2Cr-2Nb generally decreased with increasing fretting frequency. The increasing rate of oxidation at elevated temperatures led to a drop in wear at 473 K. However, fretting wear increased as the temperature was increased from 473 to 823 K. At 723 and 823 K, oxide film disruption generated cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. Both increasing slip amplitude and increasing load tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals.

Miyoshi, Kazuhisa

Fretting Fatigue of Gamma TiAl Studied

Gamma titanium-aluminum alloy (g-TiAl) is an attractive new material for aerospace applications because of its low density and high specific strength in comparison to currently used titanium and nickel-base alloys. Potential applications for this material are compressor and low-pressure turbine blades. These blades are fitted into either the compressor or turbine disks via a dovetail connection. The dovetail region experiences a complex stress state due to the alternating centrifugal force and the natural high-frequency vibration of the blade. Because of the dovetail configuration and the complex stress state, fretting is often a problem in this area. Furthermore, the local stress state becomes more complex when the influence of the metal-metal contact and the edge of the contact is evaluated. Titanium and titanium-based alloys in the clean state exhibit strong adhesive bonds when in contact with themselves and other materials (refs. 1 and 2). This adhesion causes heavy surface damage and high friction in practical cases. Although the wear produced by fretting may be mild, the reduction in fatigue life can be substantial. Thus, there is the potential for fretting problems with these TiAl applications. Since TiAl is an emerging material, there has been limited information about its fretting behavior.

Miyoshi, Kazuhisa

An Experimental Study of Fretting of Gear Teeth

Experiments were conducted to study fretting of gears. The gears were made from case-carburized AISI 9310 alloy to match the material of a flight actuator gearbox of interest. The objective of the testing was to produce damage representative of that observed on flight hardware. The following correlations and observations were noted. The amplitude of dithering motion very strongly influenced the type and magnitude of damage. Sliding amounts on the order of 30% of the width of the line contact were judged to most readily produce fretting damage. There was observed an incubation period on the order of tens-of-thousands of cycles, and the incubation period was influenced by surface roughness, torque, and the motion extent. Fretting damage could be produced for any of the torques tested, and the severity of damage increased slightly with torque. Gear teeth having surface roughness of 0.7-0.8 micrometer were somewhat more resistant to fretting than were smoother surfaces.

Krantz, Timothy L.

Formal Requirements Elicitation with FRET

FRET is a tool for writing, understanding, formalizing and analyzing requirements. Users write requirements in an intuitive, restricted natural language, called FRETISH, with precise, unambiguous meaning. For a FRETISH requirement, FRET: 1) produces natural language and diagrammatic explanations of its exact meaning, 2) formalizes the requirement in logics, and 3) supports interactive simulation of produced logic formulas to ensure that they capture user intentions. FRET connects to analysis tools by facilitating the mapping between requirements and models/code, and by generating verification code. FRET is available open source at https://github.com/NASA-SW-VnV/fret; a video can be accessed at : https://tinyurl.com/fretForREFSQ.

Giannakopoulou, Dimitra

Integrating FRET with Copilot: Automated Translation of Natural Language Requirements to Runtime Monitors

Runtime verification (RV) enables monitoring systems at runtime, to detect property violations early and limit their potential consequences. To provide the level of assurance required for ultra-critical systems, monitor specifications must faithfully reflect the original mission requirements, which are often written in ambiguous natural language. This paper presents an end-to-end framework to capture requirements in structured natural language and generate monitors that capture their semantics faithfully. We leverage NASA’s Formal Requirement Elicitation Tool (FRET), and the RV system Copilot. We extend FRET with mechanisms to capture additional information needed to generate monitors, and introduce OGMA, a new tool to bridge the gap between FRET and Copilot. With this framework, users can write requirements in an intuitive format and obtain real-time C monitors suitable for use in embedded systems. Our tool chain is available as open source.

FRET

Fretting of Secondary-Seal-Ring Candidate Materials in Air at Temperatures to 816 C

Superalloys containing chromium showed decreasing fretting damage with increasing temperature of 816 C. This trend was related to the ability of the alloys to generate self-protecting oxide films. The damage at 816 C was one-third to one-tenth of that at 23 C. Osmium, chromium, and chromium carbide platings were fretted at 23 and 450 C. Osmium was extremely protective at 23 C but oxidized excessively at 450 C. Chromium and chromium carbide gave about the same protection at 450 C as the oxide films that formed on the superalloys. High graphite and low graphite carbons were fretted at 23 and 327 C. High graphite carbon was superior at 327 C, but low graphite carbon was the best material examined at 23 C.

Bill, R. C.