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All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Subsurface Stress Fields in FCC Single Crystal Anisotropic Contacts

Single crystal superalloy turbine blades used in high pressure turbomachinery are subject to conditions of high temperature, triaxial steady and alternating stresses, fretting stresses in the blade attachment and damper contact locations, and exposure to high-pressure hydrogen. The blades are also subjected to extreme variations in temperature during start-up and shutdown transients. The most prevalent high cycle fatigue (HCF) failure modes observed in these blades during operation include crystallographic crack initiation/propagation on octahedral planes, and non-crystallographic initiation with crystallographic growth. Numerous cases of crack initiation and crack propagation at the blade leading edge tip, blade attachment regions, and damper contact locations have been documented. Understanding crack initiation/propagation under mixed-mode loading conditions is critical for establishing a systematic procedure for evaluating HCF life of single crystal turbine blades. This paper presents analytical and numerical techniques for evaluating two and three dimensional subsurface stress fields in anisotropic contacts. The subsurface stress results are required for evaluating contact fatigue life at damper contacts and dovetail attachment regions in single crystal nickel-base superalloy turbine blades. An analytical procedure is presented for evaluating the subsurface stresses in the elastic half-space, based on the adaptation of a stress function method outlined by Lekhnitskii. Numerical results are presented for cylindrical and spherical anisotropic contacts, using finite element analysis (FEA). Effects of crystal orientation on stress response and fatigue life are examined. Obtaining accurate subsurface stress results for anisotropic single crystal contact problems require extremely refined three-dimensional (3-D) finite element grids, especially in the edge of contact region. Obtaining resolved shear stresses (RSS) on the principal slip planes also involves considerable post-processing work. For these reasons it is very advantageous to develop analytical solution schemes for subsurface stresses, whenever possible.

Arakere, Nagaraj K.↗
NASA NTRS1984

A study of interply layer effects on the free-edge stress field of angleplied laminates

The general-purpose finite-element program MSC/NASTRAN is used to study the interply layer effects on the free-edge stress field of symmetric angleplied laminates subjected to uniform tensile stress. The free-edge region is modeled as a separate substructure (superelement) which enables easy mesh refinement and provides the flexibility to move the superelement along the edge. The results indicate that the interply layer reduces the stress intensity significantly at the free edge. Another important observation of the study is that the failures observed near free edges of these types of laminates could have been caused by the interlaminar shear stresses.

Murthy, P. L. N.↗
NASA NTRS1985

A study of interply layer effects on the free edge stress field of angleplied laminates

The general-purpose finite-element program MSC/NASTRAN is used to study the interply layer effects on the free-edge stress field of symmetric angleplied laminates subjected to uniform tensile stress. The free-edge region is modeled as a separate substructure (superelement) which enables easy mesh refinement and provides the flexibility to move the superelement along the edge. The results indicate that the interply layer reduces the stress intensity significantly at the free edge. Another important observation of the study is that the failures observed near free edges of these types of laminates could have been caused by the interlaminar shear stresses.

Murthy, P. L. N.↗
NASA NTRS2003

Subsurface Stress Fields in Single Crystal (Anisotropic) Contacts

Single crystal superalloy turbine blades used in high pressure turbomachinery are subject to conditions of high temperature, triaxial steady and fatigue stresses, fretting stresses in the blade attachment and damper contact locations, and exposure to high-pressure hydrogen. The blades are also subjected to extreme variations in temperature during start-up and shutdown transients. The most prevalent HCF failure modes observed in these blades during operation include crystallographic crack initiation/propagation on octahedral planes, and noncrystallographic initiation with crystallographic growth. Numerous cases of crack initiation and crack propagation at the blade leading edge tip, blade attachment regions, and damper contact locations have been documented. Understanding crack initiation/propagation under mixed-mode loading conditions is critical for establishing a systematic procedure for evaluating HCF life of single crystal turbine blades. Techniques for evaluating two and three dimensional subsurface stress fields in anisotropic contacts are presented in this report. Figure 1 shows typical damper contact locations in a turbine blade. The subsurface stress results are used for evaluating contact fatigue life at damper contacts and dovetail attachment regions in single crystal nickel-base superalloy turbine blades.

Arakere, Nagaraj K.↗
NASA NTRS1993

Spatially extensive uniform stress fields on Venus inferred from radial dike swarm geometries: The Aphrodite Terra example

The high resolution and near global coverage of Magellan radar images is facilitating attempts to systematically investigate the stresses that have deformed the venusian crust. Here we continue earlier efforts to utilize approximately 170 large, radially lineated structures interpreted as dike swarms to assess the orientation of the regional maximum horizontal compressive stress (MHCS) which existed in their vicinities during emplacement. Examination of swarms near the equator reveals a link to broad scale regional structures, such as Aphrodite Terra, across distances in excess of 1000 km, suggesting the existence of first order stress fields which affect areas of more than 10(exp 6) sq km in a uniform fashion. Focusing further upon the Aphrodite Terra region, the MHCS field in the surrounding lowlands inferred from radial swarms is oriented approximately normal to the slope of the highland topography. This stress configuration appears, at a simple level, to be incompatible with that expected during either upwelling or downwelling construction of the highlands. In addition, the relatively undeformed geometry of the radial structures within the highlands implies that these dike swarm features formed more recently than their highly deformed surroundings. We conclude that the differential stresses which existed during emplacement of the dike swarms within and adjacent to the Aphrodite Terra highlands are related to the gravitational relaxation of pre-existing topography.

Grosfils, Eric B.↗
NASA NTRS1994

On the measurement of the crack tip stress field as a means of determining Delta K(sub eff) under conditions of fatigue crack closure

The optical method of caustics has been successfully extended to enable stress intensity factors as low as 1MPa square root of m to be determined accurately for central fatigue cracks in 2024-T3 aluminium alloy test panels. The feasibility of using this technique to study crack closure, and to determine the effective stress intensity factor range, Delta K(sub eff), has been investigated. Comparisons have been made between the measured values of stress intensity factor, K(sub caus), and corresponding theoretical values, K(sub theo), for a range of fatigue cracks grown under different loading conditions. The values of K(sub caus) and K(sub theo) were in good agreement at maximum stress, where the cracks are fully open, while K(sub caus) exceeded K(sub theo) at minimum stress, due to crack closure. However, the levels of crack closure and values of Delta K(sub eff) obtained could not account for the variations of crack growth rate with loading conditions. It is concluded that the values of Delta K(sub eff), based on caustic measurements in a 1/square root of r stress field well outside the plastic zone, do not fully reflect local conditions which control crack tip behavior.

Wallhead, Ian R.↗
NASA NTRS1974

Mixed mode stress field effect in adhesive fracture

Numerical or analytical analyses were performed on seven different test specimens including blister test, 90-degree peel test, torsion test, and various cone tests. These specimens are in general subjected to complex stress fields having various amounts of Mode I, Mode II, and Mode III loads. The specimens were then constructed using polymethyl methacrylate for the adherends and a transparent polyurethane elastomer (Solithane 113) for the adhesive. This combination permitted direct observation of the bondline as load was applied. Although initial debonds as well as bond end termination singularities were present in all specimens, in some cases the debond did not initiate at the singularity points as would normally have been expected. An explanation for this behavior is presented, as well as a comparison of loading mode effect on those specimens for which the debond did propagate from a bond terminus singular point.

Anderson, G. P.↗
NASA NTRS1984

On stress field near a stationary crack tip

It is well known that the stress and elastic-plastic deformation fields near a crack tip have important roles in the corresponding fracture process. For elastic-perfectly-plastic solids, different solutions are given in the literature. In this work several of these solutions are examined and compared for Mode I (tension), Mode II (shear), and mixed Modes I and II loading conditions in plane strain. By consideration of the dynamic solution, it is shown that the assumption that the material is yielding all around a crack tip may not be reasonable in all cases. By admitting the existence of some elastic sectors, continuous stress fields are obtained even for mixed Modes I and II.

Nemat-Nasser, S.↗
NASA NTRS2004

Investigation of Three-Dimensional Stress Fields and Slip Systems for FCC Single Crystal Superalloy Notched Specimens

Metals and their alloys, except for a few intermetallics, are inherently ductile, i.e. plastic deformation precedes fracture in these materials. Therefore, resistance to fracture is directly related to the development of the plastic zone at the crack tip. Recent studies indicate that the fracture toughness of single crystals depends on the crystallographic orientation of the notch as well as the loading direction. In general, the dependence of crack propagation resistance on crystallographic orientation arises from the anisotropy of (i) elastic constants, (ii) plastic deformation (or slip), and (iii) the weakest fracture planes (e.g. cleavage planes). Because of the triaxial stress state at the notch tips, many slip systems that otherwise would not be activated during uniaxial testing, become operational. The plastic zone formation in single crystals has been tackled theoretically by Rice and his co-workers and only limited experimental work has been conducted in this area. The study of the stresses and strains in the vicinity of a FCC single crystal notch tip is of relatively recent origin. We present experimental and numerical investigation of 3D stress fields and evolution of slip sector boundaries near notches in FCC single crystal tension test specimens, and demonstrate that a 3D linear elastic finite element model that includes the effect of material anisotropy is shown to predict active slip planes and sectors accurately. The slip sector boundaries are shown to have complex curved shapes with several slip systems active simultaneously near the notch. Results are presented for surface and mid-plane of the specimens. The results demonstrate that accounting for 3D elastic anisotropy is very important for accurate prediction of slip activation near FCC single crystal notches loaded in tension. Results from the study will help establish guidelines for fatigue damage near single crystal notches.

Arakere, Nagaraj K.↗
NASA NTRS2002

Three-Dimensional Stress Fields and Slip Systems for Single Crystal Superalloy Notched Specimens

Single crystal superalloys have become increasingly popular for turbine blade and vane applications due to their high strength, and creep and fatigue resistance at elevated temperatures. The crystallographic orientation of a single crystal material greatly affects its material properties, including elastic modulus, shear modulus, and ductility. These directional properties, along with the type of loading and temperature, dictate an anisotropic response in the yield strength, creep resistance, creep rupture ductility, fatigue resistance, etc. A significant amount of research has been conducted to determine the material properties in the <001> orientation, yet the material properties deviating from the <001> orientation have not been assessed for all cases. Based on the desired application and design criteria, a crystal orientation is selected to yield the maximum properties. Currently, single crystal manufacturing is able to control the primary crystallographic orientation within 15 of the target orientation, which is an acceptable deviation to meet both performance and cost guidelines; the secondary orientation is rarely specified. A common experiment is the standard load-controlled tensile test, in which specimens with different orientations can be loaded to observe the material response. The deformation behavior of single-crystal materials under tension and compression is known to be a function of not only material orientation, but also of varying microdeformation (i.e. dislocation) mechanisms. The underlying dislocation motion causes deformation via slip, and affects the activation of specific slip systems based on load and orientation. The slip can be analyzed by observing the visible traces left on the surface of the specimen from the slip activity within the single crystal material. The goal of this thesis was to predict the slip systems activated in three-dimensional stress fields of a notched tensile specimen, as a function of crystal orientation, using finite element analysis without addressing microstructural deformation mechanisms that govern their activation. Out of three orientations tested, the specimen with a [110] load orientation and a [001] growth direction had the lowest maximum resolved shear stress; this specimen orientation appears to be the best design candidate for a tensile application.

Magnan, Shannon M.↗
NASA NTRS1992

A quasi-Hertzian stress field from an internal source: A possible working model for the Vredefort structure

The Vredefort structure is a large domal feature about 110 km southeast of Johannesburg, South Africa, situated within and almost central to the large intracratonic Witwatersrand Basin. This structure consists of an Archean core of ca. 45 km in diameter, consisting largely of granitic gneiss, surrounded by a collar of metasedimentary and metavolcanic supracrustal rocks of the Dominian Group, Witwatersrand and Ventersdorp Supergroups, and Transvaal Sequence. The interpretation of images of the gravity and magnetic fields over Vredefort has permitted the delineation of several important features of the structure and of its environment. The outline of the collar strata is a prominent feature of both the gravity and the magnetic fields. The Vredefort structure shares this distinctive geometry with other structures (e.g., Manicouagan, Decaturville, Sierra Madera) of debated impact origin. In all these, successively older strata with steep outward dips are encountered while traversing inward to the center of the structure. A further attribute of these structures is the shortening of the outcrop of a particular stratigraphic unit compared to the original perimeter of that unit. To account for the geometric attributes of the Vredefort structure a mechanical scheme is required where there is radial movement of horizontal strata toward, with uplift in, the center of the Vredefort structure. Two models can be proposed: (1) one in which there is a rapid rise and violent disruption of cover rocks in response to expansion of a fluid accumulation; and (2) one in which there is, in contrast, a nonexplosive, quasi-Hertzian stress field resulting from a diapiric process. Both models can accommodate the geometry and structural components of Vredefort.

Antoine, L. A. G.↗
NASA NTRS1980

Mantle convection pattern and subcrustal stress field under South America

The tectonic, igneous and metallogenic features of South America are discussed in terms of the crustal deformation associated with stresses due to mantle convection as inferred from the high degree harmonics in the geopotential field. The application of Runcorn's model for the laminar viscous flows in the upper mantle to satellite and gravity data results in a convection pattern which reveals the ascending flows between the descending Nazca plate and the overlying South American plate as well as segments of the descending Nazca plate beneath South America. The arc volcanism in South America is shown apparently to be related to the upwelling of high-temperature material induced by the subduction of the Nazca plate, with the South American basin systems associated with downwelling mantle flows. The resulting tensional stress fields are shown to be regions of structural kinship characterized by major concentrations of ore deposits and related to the cordillera, shield and igneous systems and the upward Andean movements. It is suggested that the upwelling convection flows in the upper mantle, coupled with crustal tension, have provided an uplift mechanism which has forced the hydrothermal systems in the basement rocks to the surface.

Liu, H.-S.↗
NASA NTRS1989

Three-dimensional analysis of surface crack-Hertzian stress field interaction

The results are presented of a stress intensity factor analysis of semicircular surface cracks in the inner raceway of an engine bearing. The loading consists of a moving spherical Hertzian contact load and an axial stress due to rotation and shrink fit. A 3-D linear elastic Boundary Element Method code was developed to perform the stress analysis. The element library includes linear and quadratic isoparametric surface elements. Singular quarter point elements were employed to capture the square root displacement variation and the inverse square root stress singularity along the crack front. The program also possesses the capability to separate the whole domain into two subregions. This procedure enables one to solve nonsymmetric fracture mechanics problems without having to separate the crack surfaces a priori. A wide range of configuration parameters was investigated. The ratio of crack depth to bearing thickness was varied from one-sixtieth to one-fifth for several different locations of the Hertzian load. The stress intensity factors for several crack inclinations were also investigated. The results demonstrate the efficiency and accuracy of the Boundary Element Method. Moreover, the results can provide the basis for crack growth calculations and fatigue life prediction.

Ballarini, R.↗
NASA NTRS1988

The stress field in an edge cracked plate in antiplane deformation

The antiplane strain problem of an edge cracked elastic plate subjected to a surface displacement load is solved, and the surface line loads are obtained using conformal mapping techniques. Results are presented for the yield, stress, strain and displacement distributions, and stress intensity factors in the plate. A superposition technique and Green's functions are used to determine the strain field on the upper plate surface due to arbitrarily applied tensile stress on the lower plate surface.

Li, V. C.↗
NASA NTRS1993

Approximating the stress field within the unit cell of a fabric reinforced composite using replacement elements

This report concerns the prediction of the elastic moduli and the internal stresses within the unit cell of a fabric reinforced composite. In the proposed analysis no restrictions or assumptions are necessary concerning yarn or tow cross-sectional shapes or paths through the unit cell but the unit cell itself must be a right hexagonal parallelepiped. All the unit cell dimensions are assumed to be small with respect to the thickness of the composite structure that it models. The finite element analysis of a unit cell is usually complicated by the mesh generation problems and the non-standard, adjacent-cell boundary conditions. This analysis avoids these problems through the use of preprogrammed boundary conditions and replacement materials (or elements). With replacement elements it is not necessary to match all the constitutional material interfaces with finite element boundaries. Simple brick-shaped elements can be used to model the unit cell structure. The analysis predicts the elastic constants and the average stresses within each constituent material of each brick element. The application and results of this analysis are demonstrated through several example problems which include a number of composite microstructures.

Foye, R. L.↗