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Advances in Integrally Formed Metallic Structures

NASA Langley Research Center (LaRC) is applying flow forming technology to aerospace aluminum alloys for the manufacture of integrally stiffened cylinders that meet aircraft fuselage or launch vehicle specifications. High-strength 2xxx series alloys, in various temper/product form conditions, are being compared with medium-strength, very formable AA 6061 as the benchmark. Screening of candidate materials traditionally relies on empirical forming trials, but more recently on metrics derived from constant nominal strain rate tensile testing. In this work, the established hierarchy of formability metrics is adopted as the baseline; tensile area reduction, work hardening exponent, and modulus of resilience. The suite of metrics can be expanded based on phenomenological and mechanistic considerations of plastic flow instabilities to incorporate anisotropy ratio, rate of work hardening, and dynamic strain aging effects. Separate research thrusts at LaRC are aimed at formulating a protocol for scalable production of fully formed, defect-free components: 1) quantifying the extended set of formability metrics from constant and jump strain rate tensile tests with digital image correlation (DIC); 2) using statistically designed experiments on a vertical spin/flow forming facility (WF VUD-600®) to isolate the effect of convenient process variables, such as axial feed rate and thickness reduction; and 3) predicting the effect of feed ratio (roller translation relative to mandrel rotation speeds) on material response via process modeling using the DEFORM® simulation software. Current results will be discussed in terms of correlating intrinsic material properties with the bulk workability characteristics to successfully fabricate cylinders with complex cross-sections.

Aluminum↗

DOE OSTI2021

Coupling dynamic in situ X-ray micro-imaging and indentation: A novel approach to evaluate micromechanics applied to oil shale

Oil and gas shales are a system where understanding the mechanical properties at the microscale is of paramount importance, e.g. to better understand the behavior of proppant-shale contacts and their role in the evolution of propped fractures in unconventional reservoirs. Here we show for the first time an experiment coupling indentation testing with in situ X-ray imaging in a Green River shale sample. A full compliance curve has been measured with the sample in water, allowing to visualize the indentation of the sample in function of axial load, in a purpose-built system for combined in situ indentation and X-ray imaging. A series of 3D datasets were used for a digital volume correlation study to obtain local strain fields. This analysis has been complemented with the analysis of cracks. Finally, geomechanical modeling has been carried out to replicate and generalize the observed behavior in the shale. This study validated this experimental approach, providing a breakthrough in understanding micro-mechanics in shales, and demonstrates how this class of experiments can be important for studies involving the prediction of the evolution of propped fractures in shale reservoirs, with possible applications in a much larger number of application fields (geothermal, materials science, etc.)

04 OIL SHALES AND TAR SANDS↗

NASA NTRS1986

Cryogenic strain gage techniques used in force balance design for the National Transonic Facility

A force balance is a strain gage transducer used in wind tunnels to measure the forces and moments on aerodynamic models. Techniques have been established for temperature-compensation of force balances to allow their use over the operating temperature range of a cryogenic wind tunnel (-190C to 60C) without thermal control. This was accomplished by using a patented strain gage matching process to minimize inherent thermal differences, and a thermal compensation procedure to reduce the remaining thermally-induced outputs to acceptable levels. A method of compensating for mechanical movement of the axial force measuring beam caused by thermally-induced stresses under transient temperatures was also included.

Ferris, A. T.↗

NASA NTRS1994

Static and dynamic force/moment measurements in the Eidetics water tunnel

Water tunnels have been utilized in one form or another to explore fluid mechanics and aerodynamics phenomena since the days of Leonardo da Vinci. Water tunnel testing is attractive because of the relatively low cost and quick turn-around time to perform flow visualization experiments and evaluate the results. The principal limitation of a water tunnel is that the low flow speed, which provides for detailed visualization, also results in very small hydrodynamic (aerodynamic) forces on the model, which, in the past, have proven to be difficult to measure accurately. However, the advent of semi-conductor strain gage technology and devices associated with data acquisition such as low-noise amplifiers, electronic filters, and digital recording have made accurate measurements of very low strain levels feasible. The principal objective of this research effort was to develop a multi-component strain gage balance to measure forces and moments on models tested in flow visualization water tunnels. A balance was designed that allows measuring normal and side forces, and pitching, yawing and rolling moments (no axial force). The balance mounts internally in the model and is used in a manner typical of wind tunnel balances. The key differences between a water tunnel balance and a wind tunnel balance are the requirement for very high sensitivity since the loads are very low (typical normal force is 0.2 lbs), the need for water proofing the gage elements, and the small size required to fit into typical water tunnel models.

Carlos J Suarez↗

NASA NTRS2014

Recent Progress in Adjustable X-ray Optics for Astronomy

Two adjustable X-ray optics approaches are being developed for thin grazing incidence optics for astronomy. The first approach employs thin film piezoelectric material sputter deposited as a continuous layer on the back of thin, lightweight Wolter-I mirror segments. The piezoelectric material is used to correct mirror figure errors from fabrication, mounting/alignment, and any ground to orbit changes. The goal of this technology is to produce Wolter mirror segment pairs corrected to 0.5 arc sec image resolution. With the combination of high angular resolution and lightweight, this mirror technology is suitable for the Square Meter Arc Second Resolution Telescope for X-rays (SMART-X) mission concept.. The second approach makes use of electrostrictive adjusters and full shell nickel/cobalt electroplated replication mirrors. An array of radial adjusters is used to deform the full shells to correct the lowest order axial and azimuthal errors, improving imaging performance from the 10 - 15 arc sec level to ~ 5 arc sec. We report on recent developments in both technologies. In particular, we discuss the use of insitu strain gauges on the thin piezo film mirrors for use as feedback on piezoelectric adjuster functionality, including their use for on-orbit figure correction. We also report on the first tests of full shell nickel/cobalt mirror correction with radial adjusters.

Reid, Paul B.↗

NASA NTRS1993

Damage tolerance of pressurized graphite/epoxy tape cylinders under uniaxial and biaxial loading

The damage tolerance behavior of internally pressurized, axially slit, graphite/epoxy tape cylinders was investigated. Specifically, the effects of axial stress, structural anisotropy, and subcritical damage were considered. In addition, the limitations of a methodology which uses coupon fracture data to predict cylinder failure were explored. This predictive methodology was previously shown to be valid for quasi-isotropic fabric and tape cylinders but invalid for structurally anisotropic (+/-45/90)(sub s) and (+/-45/0)(sub s) cylinders. The effects of axial stress and structural anisotropy were assessed by testing tape cylinders with (90/0/+/-45)(sub s), (+/-45/90)(sub s), and (+/-45/0)(sub s) layups in a uniaxial test apparatus, specially designed and built for this work, and comparing the results to previous tests conducted in biaxial loading. Structural anisotropy effects were also investigated by testing cylinders with the quasi-isotropic (0/+/-45/90)(sub s) layup which is a stacking sequence variation of the previously tested (90/0/+/-45)(sub s) layup with higher D(sub 16) and D(sub 26) terms but comparable D(sub 16) and D(sub 26) to D(sub 11) ratios. All cylinders tested and used for comparison are made from AS4/3501-6 graphite/epoxy tape and have a diameter of 305 mm. Cylinder slit lengths range from 12.7 to 50.8 mm. Failure pressures are lower for the uniaxially loaded cylinders in all cases. The smallest percent failure pressure decreases are observed for the (+/-45/90)(sub s) cylinders, while the greatest such decreases are observed for the (+/-45/0)(sub s) cylinders. The relative effects of the axial stress on the cylinder failure pressures do not correlate with the degree of structural coupling. The predictive methodology is not applicable for uniaxially loaded (+/-45/90)(sub s) and (+/-45/0)(sub s) cylinders, may be applicable for uniaxially loaded (90/0/+/-45)(sub s) cylinders, and is applicable for the biaxially loaded (90/0/+/-45)(sub s) and (0/+/-45/90)(sub s) cylinders. This indicates that the ratios of D(sub 16) and D(sub 26) to D(sub 11), as opposed to the absolute magnitudes of D(sub 16) and D(sub 26), may be important in the failure of these cylinders and in the applicability of the methodology. Discontinuities observed in the slit tip hoop strains for all the cylinders tested indicate that subcritical damage can play an important role in the failure of tape cylinders. This role varies with layup and loading condition and is likely coupled to the effects of structural anisotropy. Biaxial failure pressures may exceed the uniaxial values because the axial stress contributes to the formation of 0 deg ply splitting (accompanied by delamination) or similar stress-mitigating subcritical damage. The failure behavior of similar cylinders can also vary as a result of differences in the role of subcritical damage as observed for the case of a biaxially loaded (90/0/+/-45)(sub s) cylinder with a 12.7 mm slit. For this case, the methodology is valid when the initial coupon and cylinder fracture modes agree. However, the methodology underpredicts the failure pressure of the cylinder when a circumferential fracture path, suggestive of a 0 deg ply split, occurs at one slit tip. Thus, the failure behavior of some tape cylinders may be highly sensitive to the initial subcritical damage mechanism. Finite element analyses are recommended to determine how structural anisotropy and axial stress modify the slit tip stress states in cylinders from those found in flat plates since similarity of these stress states is a fundamental assumption of the current predictive methodology.

Priest, Stacy Marie↗

NASA NTRS1994

Development of a multicomponent force and moment balance for water tunnel applications, volume 1

The principal objective of this research effort was to develop a multicomponent strain gauge balance to measure forces and moments on models tested in flow visualization water tunnels. An internal balance was designed that allows measuring normal and side forces, and pitching, yawing and rolling moments (no axial force). The five-components to applied loads, low interactions between the sections and no hysteresis. Static experiments (which are discussed in this Volume) were conducted in the Eidetics water tunnel with delta wings and a model of the F/A-18. Experiments with the F/A-18 model included a thorough baseline study and investigations of the effect of control surface deflections and of several Forebody Vortex Control (FVC) techniques. Results were compared to wind tunnel data and, in general, the agreement is very satisfactory. The results of the static tests provide confidence that loads can be measured accurately in the water tunnel with a relatively simple multicomponent internal balance. Dynamic experiments were also performed using the balance, and the results are discussed in detail in Volume 2 of this report.

Suarez, Carlos J.↗

DOE OSTI2021

Deformation and strength of mantle relevant garnets: Implications for the subduction of basaltic-rich crust

Garnet is an important mineral phase in the upper mantle as it is both a key component in bulk mantle rocks, and a primary phase at high pressure within subducted basalt. In this work, we focus on the strength of garnet and the texture that develops within garnet during accommodation of differential deformational strain. We use X-ray diffraction in a radial geometry to analyze texture development in situ in three garnet compositions under pressure at 300 K: a natural garnet (Prp 60 Alm 37 ) to 30 GPa, and two synthetic majorite-bearing compositions (Prp 59 Maj 41 and Prp 42 Maj 58 ) to 44 GPa. All three garnets develop a modest (100) texture at elevated pressure under axial compression. Elasto-viscoplastic self-consistent (EVPSC) modeling suggests that two slip systems are active in the three garnet compositions at all pressures studied: {110}<$1\bar{1}1$> and {001}<110>. We determine a flow strength of ~5 GPa at pressures between 10 to 15 GPa for all three garnets; these values are higher than previously reported yield strengths measured on natural and majoritic garnets. Strengths calculated using the experimental lattice strain differ from the strength generated from those calculated using EVPSC. Prp 67 Alm 33 , Prp 59 Maj 41 , and Prp 42 Maj 58 are of comparable strength to each other at room temperature, which indicates that majorite substitution does not greatly affect the strength of garnets. Additionally, all three garnets are of similar strength as lower mantle phases such as bridgmanite and ferropericlase, suggesting that garnet may not be notably stronger than the surrounding lower mantle/deep upper mantle phases at the base of the upper mantle.

58 GEOSCIENCES↗

DOE OSTI2021

Experimental Capabilities to Support Design, Development and Demonstration of Microreactors

This work provides a summary of selected experimental capabilities being developed to support non-nuclear demonstration of microreactors under the U.S. Department of Energy’s (DOE’s) Microreactor Program. Major capabilities include the single primary heat extraction and removal emulator (SPHERE) and the microreactor agile non-nuclear experimental test bed (MAGNET). The SPHERE facility allows for controlled testing of the steady-state and transient heat rejection capabilities of a single heat pipe using electrical heaters that simulate nuclear heating. The facility is capable of monitoring axial temperature profiles along the heat pipe and surrounding test articles during startup, steady-state operation, and transients. Instrumentation includes non-contact infrared thermal imaging, surface thermocouples, spatially distributed fiber-optic temperature and strain sensors, electrical power meters, and a water-cooled, gas gap calorimeter for quantifying heat rejection from the heat pipe. The facility can be operated under both vacuum and inert-gas conditions.

42 ENGINEERING↗

DOE OSTI2024

Specifications of Cladding Diameter Measurements Conducted at AGHCF

Fuel element diameter data was collected on-site at the Alpha-Gamma Hot Cell Facility (AGHCF) before and after out-of-pile furnace transient tests of fuel elements. Available data records have been collected and preserved in the Out-of-Pile Transient Database (OPTD). This data is used to determine the transient-induced changes in fuel element diameter, or cladding strain, for the Whole Pin Furnace (WPF) tests. Fuel element diameter was measured by contact profilometry along the length of the fuel pin at specified rotational orientations and/or by a manually operated micrometer at several discrete axial locations along the pin. The Alpha-Gamma Hot Cell Facility Operations Manual details the way the facility operated, organizational and oversight responsibilities, and procedures for examination of samples. The working version of the manual at the time of the whole pin furnace tests and the test pin examinations is Doc. No. IPS-2-00-00, dated June 1989. This specification was developed using the operations manual and recovered measurement records in consultation with subject matter experts (SMEs). The measurement methods, format of the available post-test examination (PTE) data, and recommended methods for use and interpretation of that data are summarized. Section 2 describes the available diameter measurement data for the WPF tests with guidance for interpretation and usage, and Section 3 describes the instrument measurement procedures and calibration methods.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1996

Design and evaluation of a bolted joint for a discrete carbon-epoxy rod-reinforced hat section

The use of prefabricated pultruded carbon-epoxy rods has reduced the manufacturing complexity and costs of stiffened composite panels while increasing the damage tolerance of the panels. However, repairability of these highly efficient discrete stiffeners has been a concern. Design, analysis, and test results are presented in this paper for a bolted-joint repair for the pultruded rod concept that is capable of efficiently transferring axial loads in a hat-section stiffener on the upper skin segment of a heavily loaded aircraft wing component. A tension and a compression joint design were evaluated. The tension joint design achieved approximately 1.0% strain in the carbon-epoxy rod-reinforced hat-section and failed in a metal fitting at 166% of the design ultimate load. The compression joint design failed in the carbon-epoxy rod-reinforced hat-section test specimen area at approximately 0.7% strain and at 110% of the design ultimate load. This strain level of 0.7% in compression is similar to the failure strain observed in previously reported carbon-epoxy rod-reinforced hat-section column tests.

Rousseau, Carl Q.↗

NASA NTRS2011

Structural Efficiency and Behavior of Pristine and Notched Stitched Structure

Two driving factors in aircraft panel design are structural efficiency and response to in-service damage. Stitching through the thickness can improve both of these considerations. Combining stitching with a post-buckling design approach can provide additional improvements. The buckling behavior of stitched structure is considered since lighter structures can be achieved if local skin buckling is allowed to occur at less than design ultimate load. Through-the-thickness stitching can suppress delamination between skin and flange, thereby allowing the structure to reliably carry load into the postbuckling range. Hat-stiffened and rod-stiffened panels in which the skin and flanges were stitched together through-the-thickness prior to curing are considered through experiment and analysis. In both types of panels no mechanical fasteners were used for the assembly. Specimens were loaded to failure in axial compression. In this study all specimens buckled in the skin between the stiffeners and continued to carry load. In addition, the behavior of panels with a severed stringer or notch are considered. Failure loads and strain distributions in the notched panel are compared to those in the unnotched panel.

Jegley, Dawn C.↗

DOE OSTI2021

Evolution of texture and internal stresses within polycrystalline rock salt using in situ 3D synchrotron computed tomography and 3D X-ray diffraction

Over time rock salt caverns have been extensively used as reliable repositories for hazardous waste such as nuclear waste, oil or compressed gases. Undisturbed rock salt deposits in nature are usually impermeable and have very low porosity. However, rock salt formations under excavation stresses can develop crack networks, which increase their porosities; and in the case of a connected crack network within the media, rock salt may become permeable. Although the relationship between the permeability of rock salt and the applied stresses has been reported in the literature, a microscopic study that investigates the properties influencing this relationship, such as the evolution of texture and internal stresses, has yet to be conducted. This study employs in situ 3D synchrotron micro-computed tomography and 3D X-ray diffraction (3DXRD) on two small-scale polycrystalline rock salt specimens to investigate the evolution of the texture and internal stresses within the specimens. The 3DXRD technique measures the 3D crystal structure and lattice strains within rock salt grains. The specimens were prepared under 1D compression conditions and have shown an initial {111} preferred texture, a dominant {110}$\langle1\bar{1}0\rangle$ slip system and no fully connected crack network. The {111} preferred texture under the unconfined compression experiment became stronger, while the {111}$\langle1\bar{1}0\rangle$ slip system became more prominent. The specimens did not have a fully connected crack network until applied axial stresses reached about 30 MPa, at a point where the impermeability of the material becomes compromised due to the development of multiple major cracks.

36 MATERIALS SCIENCE↗

NASA NTRS1973

Evaluation of Stress Corrosion Cracking Susceptibility Using Fracture Mechanics Techniques, Part 1

Stress corrosion cracking (SSC) tests were performed on 13 aluminum alloys, 13 precipitation hardening stainless steels, and two titanium 6Al-4V alloy forgings to compare fracture mechanics techniques with the conventional smooth specimen procedures. Commercially fabricated plate and rolled or forged bars 2 to 2.5-in. thick were tested. Exposures were conducted outdoors in a seacoast atmosphere and in an inland industrial atmosphere to relate the accelerated tests with service type environments. With the fracture mechanics technique tests were made chiefly on bolt loaded fatigue precracked compact tension specimens of the type used for plane-strain fracture toughness tests. Additional tests of the aluminum alloy were performed on ring loaded compact tension specimens and on bolt loaded double cantilever beams. For the smooth specimen procedure 0.125-in. dia. tensile specimens were loaded axially in constant deformation type frames. For both aluminum and steel alloys comparative SCC growth rates obtained from tests of precracked specimens provide an additional useful characterization of the SCC behavior of an alloy.

Sprowls, D. O.↗

NASA NTRS1982

Strain-Gaged Bolts Are Easily Prepared

New method for installing strain gages in structural bolts is implemented as standard workbench procedure. Rather than potting gages in a hole along axis of bolt, gages are first installed on outside of plastic carrier tube. Tube is then epoxied in axial hole. Procedure can be used to prepare gages to monitor bolt tension, shear, or torsion.

Walker, R. L.↗

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.↗

NASA NTRS1991

Fiber Creep Evaluation by Stress Relaxation Measurements

A simple bend stress relaxation (BSR) test has been used to measure the creep related properties of a chemically vapor-deposited SiC fiber. Time, temperature, and strain dependent BSR data were analyzed to ascertain the ability of the stress relaxation results to predict tensile creep as a function of the same parameters. The predictions compared very well to actual creep data obtained by axial measurements, indicating that the BSR test could be used for determining both creep and stress relaxation of polycrystalline ceramic fibers under tensile loading.

Morscher, Gregory N.↗