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Bileaf lever detects small deformations by highly magnifying linear displacements. Device is applicable to force measuring instruments, pressure cells, temperature gages, existing strain gages, dial gages, or extensometers. Additional magnification is obtained by cementing a small mirror to mobile end of bileaf.
A ceramic strain gage based on reactively sputtered indium-tin-oxide (ITO) thin films is used to monitor the structural integrity of components employed in aerospace propulsion systems operating at temperatures in excess of 1500.degree. C. A scanning electron microscopy (SEM) of the thick ITO sensors reveals a partially sintered microstructure comprising a contiguous network of submicron ITO particles with well defined necks and isolated nanoporosity. Densification of the ITO particles was retarded during high temperature exposure with nitrogen thus stabilizing the nanoporosity. ITO strain sensors were prepared by reactive sputtering in various nitrogen/oxygen/argon partial pressures to incorporate more nitrogen into the films. Under these conditions, sintering and densification of the ITO particles containing these nitrogen rich grain boundaries was retarded and a contiguous network of nano-sized ITO particles was established.
A demonstration test of burner liner strain measurements using resistance strain gages as well as a feasibility test of an optical speckle technique for strain measurement are presented. The strain gage results are reported. Ten Kanthal A-1 wire strain gages were used for low cycle fatigue strain measurements to 950 K and .002 apparent strain on a JT12D burner can in a high pressure (10 atmospheres) burner test. The procedure for use of the strain gages involved extensive precalibration and postcalibration to correct for cooling rate dependence, drift, and temperature effects. Results were repeatable within + or - .0002 to .0006 strain, with best results during fast decels from 950 K. The results agreed with analytical prediction based on an axisymmetric burner model, and results indicated a non-uniform circumferential distribution of axial strain, suggesting temperature streaking.
The Langley Research Center uses strain gages in a wide variety of demanding test environments. Strain gage installations, depending on the testing scenario, may see high temperatures, cryogenic temperature, moisture accumulation, mechanical abuse, or any combination of these conditions. At Langley, there is often a need to provide protection for strain gages against moisture and mechanical abuse, especially when large-scale, harsh environment testing is to be encountered. This technical memorandum discusses the evaluation of a room temperature curing silicone rubber sealant manufactured by the General Electric Company for consideration as a moisture-barrier for certain strain gage installations.
Criteria are discussed that may be used for the detection of load and gage output repeats of wind tunnel strain-gage balance data. First, empirical thresholds are introduced that help determine if the loads or electrical outputs of a pair of balance calibration or check load data points match. A threshold of 0.01 percent of the load capacity is suggested for the identification of matching loads. Similarly, a threshold of 0.1 microV/V is recommended for the identification of matching electrical outputs. Two examples for the use of load and output repeats are discussed to illustrate benefits of the implementation of a repeat point detection algorithm in a balance data analysis software package. The first example uses the suggested load threshold to identify repeat data points that may be used to compute pure errors of the balance loads. This type of analysis may reveal hidden data quality issues that could potentially be avoided by making calibration process improvements. The second example uses the electrical output threshold for the identification of balance fouling. Data from the calibration of a six-component force balance is used to illustrate the calculation of the pure error of the balance loads.
For several decades, calibrated strain gages have been used to measure loads on airplanes. The accuracy of the equations used to relate the strain gage measurements to the applied loads has been based primarily on the results of the load calibration. An approach is presented for studying the effect of widely varying load distributions on strain gage load equations. The computational procedure provides a link between the load calibration and the load to be measured in flight. A matrix approach to equation selection is presented, which is based on equation standard error, load distribution, and influence coefficient plots of the strain gage equations, and is applied to a complex, delta-wing structure.
Researchers at the NASA Lewis Research Center have developed a unique strain gage and adhesive system for measuring the mechanical properties of polymers and polymer composites at elevated temperatures. This system overcomes some of the problems encountered in using commercial strain gages and adhesives. For example, typical commercial strain gage adhesives require a postcure at temperatures substantially higher than the maximum test temperature. The exposure of the specimen to this temperature may affect subsequent results, and in some cases may be higher than the glass-transition temperature of the polymer. In addition, although typical commercial strain gages can be used for short times at temperatures up to 370 C, their long-term use is limited to 230 C. This precludes their use for testing some high-temperature polyimides near their maximum temperature capability. Lewis' strain gage and adhesive system consists of a nonencapsulated, unbacked gage grid that is bonded directly to the polymer after the specimen has been cured but prior to the normal postcure cycle. The gage is applied with an adhesive specially formulated to cure under the specimen postcure conditions. Special handling, mounting, and electrical connection procedures were developed, and a fixture was designed to calibrate each strain gage after it was applied to a specimen. A variety of tests was conducted to determine the performance characteristics of the gages at elevated temperatures on PMR-15 neat resin and titanium specimens. For these tests, which included static tension, thermal exposure, and creep tests, the gage and adhesive system performed within normal strain gage specifications at 315 C. An example of the performance characteristics of the gage can be seen in the figure, which compares the strain gage measurement on a polyimide specimen at 315 C with an extensometer measurement.
A dual strain gage balance system for measuring normal and axial forces and pitching moment of a metric airfoil model imparted by aerodynamic loads applied to the airfoil model during wind tunnel testing includes a pair of non-metric panels being rigidly connected to and extending towards each other from opposite sides of the wind tunnel, and a pair of strain gage balances, each connected to one of the non-metric panels and to one of the opposite ends of the metric airfoil model for mounting the metric airfoil model between the pair of non-metric panels. Each strain gage balance has a first measuring section for mounting a first strain gage bridge for measuring normal force and pitching moment and a second measuring section for mounting a second strain gage bridge for measuring axial force.
HITEC Corporation developed a strain gage application for DanteII, a mobile robot developed for NASA. The gage measured bending forces on the robot's legs and warned human controllers when acceptable forces were exceeded. HITEC further developed the technology for strain gage services in creating transducers out of "Indy" racing car suspension pushrods, NASCAR suspension components and components used in motion control.
An electrical resistance strain gage that can supply accurate static strain measurement for NASP application is being developed both in thin film and fine wire forms. This gage is designed to compensate for temperature effects on substrate materials with a wide range of thermal expansion coefficients. Some experimental results of the wire gage tested on one of the NASP structure materials, i.e., titanium matrix composites, are presented.
This report will provide a review of efforts to establish a set of strain gage selection guidelines for textile reinforced composite materials. A variety of strain gages were evaluated in the study to determine the sensitivity of strain measurements to the size of the strain gage. The strain gages were chosen to provide a range of gage lengths and widths. The gage aspect ratio (the length-to-width ratio) was also varied. The gages were tested on a diverse collection of textile composite laminates. Test specimens featured eleven different textile architectures: four 2-D triaxial braids, six 3-D weaves, and one stitched uniweave architecture. All specimens were loaded in uniaxial tension. The materials' moduli were measured in both the longitudinal (parallel to the O deg. yarns) and the transverse (perpendicular to the O deg. yarns) directions. The results of these measurements were analyzed to establish performance levels for extensometers and strain gages on textile composite materials. Conclusions are expressed in a summary that discusses instrumentation practices and defines strain gage selection criteria.
Two microprocessor-based multichannel monitors for monitoring strain gage signals during aerodynamic instability (flutter) testing in production type turbojet engines were described. One system monitors strain gage signals in the time domain and gives an output indication whenever the signal amplitude of any gage exceeds a pre-set alarm or abort level for that particular gage. The second system monitors the strain gage signals in the frequency domain and therefore is able to use both the amplitude and frequency information. Thus, an alarm signal is given whenever the spectral content of the strain gage signal exceeds, at any point, its corresponding amplitude vs. frequency limit profiles. Each system design is described with details on design trade-offs, hardware, software, and operating experience.
Indium-tin-oxide (ITO) thin film strain gages were successfully demonstrated at temperatures beyond 1500 C. High temperature static strain tests revealed that the piezoresistive response and electrical stability of the ceramic sensors depended on the thickness of the ITO films comprising the active strain elements. When 2.5 microns-thick ITO films were employed as the active strain elements, the piezoresistive response became unstable at temperatures above 1225 C. In contrast to this, ceramic sensors prepared with 5 microns-thick ITO were stable beyond 1430 C and sensors prepared with 8 microns-thick ITO survived more than 20 hr of operation at 1481 C. Very thick (10 microns) ITo strain gages were extremely stable and responsive at 1528 C. ESCA depth profiles confirmed that an interfacial reaction between the ITO strain gage and alumina substrate was responsible for the high temperature electrical stability observed. Similar improvements in high temperature stability were achieved by doping the active ITO strain elements with aluminum. Several Sic-Sic CMC constant strain beams were instrumented with ITO strain gages and delivered to NASA for testing. Due to the extreme surface roughness of the CMC substrates, new lithography techniques and surface preparation methods were developed. These techniques relied heavily on a combination of Sic and A12O3 cement layers to provide the necessary surface finish for efficient pattern transfer. Micro-contact printing using soft lithography and PDMS stamps was also used to successfully transfer the thin film strain gage patterns to the resist coated CMC substrates. This latter approach has considerable potential for transferring the thin film strain gage patterns to the extremely rough surfaces associated with the CMC's.
Significant strain-gage errors may exist in measurements acquired in transient-temperature environments if conventional correction methods are applied. As heating or cooling rates increase, temperature gradients between the strain-gage sensor and substrate surface increase proportionally. These temperature gradients introduce strain-measurement errors that are currently neglected in both conventional strain-correction theory and practice. Therefore, the conventional correction theory has been modified to account for these errors. A new experimental method has been developed to correct strain-gage measurements acquired in environments experiencing significant temperature transients. The new correction technique has been demonstrated through a series of tests in which strain measurements were acquired for temperature-rise rates ranging from 1 to greater than 100 degrees F/sec. Strain-gage data from these tests have been corrected with both the new and conventional methods and then compared with an analysis. Results show that, for temperature-rise rates greater than 10 degrees F/sec, the strain measurements corrected with the conventional technique produced strain errors that deviated from analysis by as much as 45 percent, whereas results corrected with the new technique were in good agreement with analytical results.
Two microprocessor-based multichannel monitors are described for monitoring strain gage signals during aerodynamic instability (flutter) testing in production type turbojet engines. One system monitors strain gage signals in the time domain and gives an output indication whenever the signal amplitude of any gage exceeds a pre-set alarm or abort level for that particular gage. The second system monitors the strain gage signals in the frequency domain and therefore is able to use both the amplitude and frequency information. Thus, an alarm signal is given whenever the spectral content of the strain gage signal exceeds, at any point, its corresponding amplitude vs frequency limit profile. Each system design is described with details on design trade-offs, hardware, software, and operating experience.
Sputtered thin-film dynamic strain gages of 2 millimeter (0.08 in) gage length and 10 micrometer (0.0004 in) thickness were fabricated on turbojet engine blades and tested in a simulated compressor environment. Four designs were developed, two for service to 600 K (600 F) and two for service to 900 K (1200 F). The program included a detailed study of guidelines for formulating strain-gage alloys to achieve superior dynamic and static gage performance. The tests included gage factor, fatigue, temperature cycling, spin to 100,000 G, and erosion. Since the installations are 30 times thinner than conventional wire strain gage installations, and any alteration of the aerodynamic, thermal, or structural performance of the blade is correspondingly reduced, dynamic strain measurement accuracy higher than that attained with conventional gages is expected. The low profile and good adherence of the thin film elements is expected to result in improved durability over conventional gage elements in engine tests.
Methods and devices for installing in a tubular shaft multiple strain gages are disclosed with focus on a method and a device for pneumatically forcing strain gages into seated engagement with the internal surfaces of a tubular shaft in an installation of multiple strain gages in a tubular shaft. The strain gages or other electron devices are seated in a template-like component which is wrapped about a pneumatically expansible body. The component is inserted into a shaft and the body is pneumatically expanded after a suitable adhesive was applied to the surfaces.
A PdCr based electrical resistance strain gage was demonstrated in the laboratory to be a viable sensor candidate for static strain measurement at high temperatures. However, difficulties were encountered while transferring the sensor to field applications. This paper is therefore prepared for recognition and resolution of the problems likely to be encountered with PdCr strain gages in field applications. Errors caused by the measurement system, installation technique and lead wire attachment are discussed. The limitations and some considerations related to the temperature compensation technique used for this gage are also addressed.