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At least 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Reliability of degrading dynamic systems subject to dynamic random loads

Reliability was determined for two degrading dynamic systems subject to random load processes. Damage is caused by loss of components for Daniels systems and crack extension for plates with cracks. The analysis accounted for the coupling between response and current damage state of the system. It is based on mean crossing rates of conditional processes and properties of diffusion models. Simple systems are used to illustrate proposed methods for estimating reliability.

Grigoriu, Mircea↗
NASA NTRS1994

Initiation and propagation of small corner cracks

The behaviour of small corner cracks, inclined or perpendicular to loading direction, is presented. There are two aspects to this investigation: initiation of small cracks and monitoring their subsequent growth. An initial pre-cracking procedure under cyclic compression is adopted to minimize the residual damage at the tip of the growing and self-arresting crack under cyclic compression. A final fatigue specimen, cut from the larger pre-cracked specimen, has two corner flaws. The opening load of corner flaw is monitored using a novel strain gauge approach. The behaviour of small corner cracks is described in terms of growth rate relative to the size of the crack and its shape.

Ellyin, Ferdnand↗
NASA NTRS2020

Microscale Characterization of Damage Accumulation in CMCs

The developing roles of damage mechanisms in the failure response of SiC/SiC minicomposites was investigated by the characterization of microscale damage accumulation with respect to microstructure. A multi-modal approach combining spatially resolved acoustic emission (AE) with tensile testing in-SEM (scanning electron microscope) was used to simultaneously examine surface (observed in-SEM) and bulk damage (monitored via AE). Strong agreement was shown between the evolving crack density estimated by AE and in-SEM measurements. The following were observed: (i) in-plane matrix content and distribution impacted crack growth; (ii) spatially-distributed matrix cracks generated varying stress-dependent AE; and (iii) certain individual cracks became more probable failure locations due to unique combinations of damage mechanisms that drove their growth. This approach enabled characterizing potential failure determinants and suggests that early damage behavior is related to certain microstructural features (e.g. surface flaws), while subsequent damage behavior is coupled to interactions of local mechanisms evolving with stress.

ceramic matrix composites↗
NASA NTRS2013

Vibration Based Sun Gear Damage Detection

Seeded fault experiments were conducted on the planetary stage of an OH-58C helicopter transmission. Two vibration based methods are discussed that isolate the dynamics of the sun gear from that of the planet gears, bearings, input spiral bevel stage, and other components in and around the gearbox. Three damaged sun gears: two spalled and one cracked, serve as the focus of this current work. A non-sequential vibration separation algorithm was developed and the resulting signals analyzed. The second method uses only the time synchronously averaged data but takes advantage of the signal/source mapping required for vibration separation. Both algorithms were successful in identifying the spall damage. Sun gear damage was confirmed by the presence of sun mesh groups. The sun tooth crack condition was inconclusive.

diagnostics↗
NASA NTRS1994

Assessment of impact damage of composite rocket motor cases

This contract reviewed the available literature on mechanisms of low velocity impact damage in filament wound rocket motor cases, MDE methods to quantify damage, critical coupon level test methods, manufacturing and material process variables and empirical and analytical modeling off impact damage. The critical design properties for rocket motor cases are biaxial hoop and axial tensile strength. Low velocity impact damage is insidious because it can create serious nonvisible damage at very low impact velocities. In thick rocket motor cases the prevalent low velocity impact damage is fiber fracture and matrix cracking adjacent to the front face. In contrast, low velocity loading of thin wall cylinders induces flexure, depending on span length and the flexure induces delamination and tensile cracking on the back face wall opposed to impact occurs due to flexural stresses imposed by impact loading. Important NDE methods for rocket motor cases are non-contacting methods that allow inspection from one side. Among these are vibrothermography, and pulse-echo methods based on acoustic-ultrasonic methods. High resolution techniques such as x-ray computed tomography appear to have merit for accurate geometrical characterization of local damage to support development of analytical models of micromechanics. The challenge of coupon level testing is to reproduce the biaxial stress state that the full scale article experiences, and to determine how to scale the composite structure to model full sized behavior. Biaxial tensile testing has been performed by uniaxially tensile loading internally pressurized cylinders. This is experimentally difficult due to gripping problems and pressure containment. Much prior work focused on uniaxial tensile testing of model filament wound cylinders. Interpretation of the results of some studies is complicated by the fact that the fabrication process did not duplicate full scale manufacturing. It is difficult to scale results from testing subscale cylinders since there are significant differences in out time of the resins relative to full scale cylinder fabrication, differences in hoop fiber tensioning and unsatisfactory coupon configurations. It appears that development of a new test method for subscale cylinders is merited. Damage tolerance may be improved by material optimization that uses fiber treatments and matrix modifications to control the fiber matrix interface bonding. It is difficult to develop process optimization in subscale cylinders without also modeling the longer out times resins experience in full scale testing. A major breakthrough in characterizing the effect of impact damage on residual strength, and understanding how to scale results of subscale evaluations, will be a sound micromechanical model that described progressive failure of the composite. Such models will utilize a three dimensional stress analysis due to the complex nature of low velocity impact stresses in thick composites. When these models are coupled with non-contact NDE methods that geometrically characterize the damage and acoustic methods that characterize the effective local elastic properties, accurate assessment of residual strength from impact damage may be possible. Directions for further development are suggested.

Paris, Henry G.↗
NASA NTRS2012

Test Analysis Correlation of the Single Stringer Bending Tests for the Space Shuttle ET-137 Intertank Stringer Crack Investigation

On November 5, 2010, Space Shuttle mission STS-133 was scrubbed due to a hydrogen leak at the Ground Umbilical Carrier Plate (GUCP). After the scrub, a crack in the foam thermal protection system (TPS) was observed on the External Tank (ET) near the interface between the liquid oxygen (LOX) tank and the Intertank. When the damaged foam was removed, two 9-in. long cracks were found on the feet of Intertank stringer S7-2, and the stringer failure was the cause of the TPS crack. An investigation was conducted to determine the root cause of the cracks, establish a remedy/repair for the stringers, and provide flight rationale for the damaged tank, ET-137. The Space Transportation System (STS) Super Lightweight ET (SLWT) is comprised of two propellant tanks (an aft liquid hydrogen (LH2) tank and a forward LOX tank) and an Intertank. The Intertank serves as the structural connection between the two propellant tanks and also functions to receive and distribute all thrust loads from the solid rocket boosters . The Intertank is a stiffened cylinder structure consisting of eight mechanically joined panels (two integrally-stiffened, machined thrust panels to react the booster loads and six stringer-stiffened skin panels). There are one main ring frame, four intermediate ring frames, and forward and aft flange chords that mate to the respective propellant tanks.. The skin/stringer panels utilize external hat-section stringers that are mechanically attached with rivets along most of their length and with specialty fasteners, such as GP Lockbolts and Hi-Loks, at the forward and aft ends where the stringers attach to the flange chords. During the STS-133 Intertank stringer crack investigation, cracks were found on a total of five stringers. All of the cracks were at the LOX end, in the feet of the stringers, and near the forward fasteners (GP Lockbolts). Video of tanking for the November 5 launch attempt was used to determine that the TPS failure, and thus the stringer failure, occurred as the LOX liquid level crossed the LOX tank / Intertank interface ring frame. Hence, cryogenically-induced displacements were suspected as a contributing cause of the stringer cracks. To study the behavior of Intertank stringers subjected to similar displacements, static load tests of individual stringers, colloquially known as "single stringer bending tests" were performed. Approximately thirty stringers were tested, many of which were cut from the partially completed Intertank for what would have been ET-139. In addition to the tests, finite element (FE) analyses of the test configuration were also performed. In this paper, the FE analyses and test-analysis correlation for stringer test S6-8 are presented. Stringer S6-8 is a "short chord" configuration with no doubler panels.

Phillips, Dawn R.↗
NASA NTRS1983

Eddy-Current Damage Test for Carbon Composites

Nondestructive test method detects cracks in materials of low conductivity. Test setup includes eddycurrent unit with frequency of 2 to 20 MHz/ and storage oscilloscope. High frequency required to assure depth of penetration less than substrate thickness, to prevent thickness from influencing reading. Eddy-current analysis confirmed by visual inspection as damaged area was sectioned and evaluated.

Hamilton, A. B.↗
NASA NTRS1994

Evaluation of the fuselage lap joint fatigue and terminating action repair

Terminating action is a remedial repair which entails the replacement of shear head countersunk rivets with universal head rivets which have a larger shank diameter. The procedure was developed to eliminate the risk of widespread fatigue damage (WFD) in the upper rivet row of a fuselage lap joint. A test and evaluation program has been conducted by Foster-Miller, Inc. (FMI) to evaluate the terminating action repair of the upper rivet row of a commercial aircraft fuselage lap splice. Two full scale fatigue tests were conducted on fuselage panels using the growth of fatigue cracks in the lap joint. The second test was performed to evaluate the effectiveness of the terminating action repair. In both tests, cyclic pressurization loading was applied to the panels while crack propagation was recorded at all rivet locations at regular intervals to generate detailed data on conditions of fatigue crack initiation, ligament link-up, and fuselage fracture. This program demonstrated that the terminating action repair substantially increases the fatigue life of a fuselage panel structure and effectively eliminates the occurrence of cracking in the upper rivet row of the lap joint. While high cycle crack growth was recorded in the middle rivet row during the second test, failure was not imminent when the test was terminated after cycling to well beyond the service life. The program also demonstrated that the initiation, propagation, and linkup of WFD in full-scale fuselage structures can be simulated and quantitatively studied in the laboratory. This paper presents an overview of the testing program and provides a detailed discussion of the data analysis and results. Crack distribution and propagation rates and directions as well as frequency of cracking are presented for both tests. The progression of damage to linkup of adjacent cracks and to eventual overall panel failure is discussed. In addition, an assessment of the effectiveness of the terminating action repair and the occurrence of cracking in the middle rivet row is provided, and conclusions of practical interest are drawn.

Samavedam, Gopal↗
NASA NTRS2003

An Experimental Investigation of Damage Resistances and Damage Tolerance of Composite Materials

The project included three lines of investigation, aimed at a better understanding of the damage resistance and damage tolerance of pultruded composites. The three lines of investigation were: (i) measurement of permanent dent depth after transverse indentation at different load levels, and correlation with other damage parameters such as damage area (from x-radiography) and back surface crack length, (ii) estimation of point stress and average stress characteristic dimensions corresponding to measured damage parameters, and (iii) an attempt to measure the damage area by a reflection photoelastic technique. All the three lines of investigation were pursued.

Prabhakaran, R.↗
NASA NTRS1997

The Characteristics of Fatigue Damage in the Fuselage Riveted Lap Splice Joint

An extensive data base has been developed to form the physical basis for new analytical methodology to predict the onset of widespread fatigue damage in the fuselage lap splice joint. The results of detailed destructive examinations have been cataloged to describe the physical nature of MSD in the lap splice joint. ne catalog includes a detailed description, e.g., crack initiation, growth rates, size, location, and fracture morphology, of fatigue damage in the fuselage lap splice joint structure. Detailed examinations were conducted on a lap splice joint panel removed from a full scale fuselage test article after completing a 60,000 cycle pressure test. The panel contained a four bay region that exhibited visible outer skin cracks and regions of crack link-up along the upper rivet row. Destructive examinations revealed undetected fatigue damage in the outer skin, inner skin, and tear strap regions. Outer skin fatigue cracks were found to initiate by fretting damage along the faying surface. The cracks grew along the faying surface to a length equivalent to two to three skin thicknesses before penetrating the outboard surface of the outer skin. Analysis of fracture surface marker bands produced during full scale testing revealed that all upper rivet row fatigue cracks contained in a dim bay region grow at similar rates; this important result suggests that fracture mechanics based methods can be used to predict the growth of outer skin fatigue cracks in lap splice structure. Results are presented showing the affects of MSD and out-of-plane pressure loads on outer skin crack link-up.

Piascik, Robert S.↗
NASA NTRS1988

Towards a damage tolerance philosophy for composite materials and structures

A damage-threshold/fail-safe approach is proposed to ensure that composite structures are both sufficiently durable for economy of operation, as well as adequately fail-safe or damage tolerant for flight safety. Matrix cracks are assumed to exist throughout the off-axis plies. Delamination onset is predicted using a strain energy release rate characterization. Delamination growth is accounted for in one of three ways: either analytically, using delamination growth laws in conjunction with strain energy release rate analyses incorporating delamination resistance curves; experimentally, using measured stiffness loss; or conservatively, assuming delamination onset corresponds to catastrophic delamination growth. Fail-safety is assessed by accounting for the accumulation of delaminations through the thickness. A tension fatigue life prediction for composite laminates is presented as a case study to illustrate how this approach may be implemented. Suggestions are made for applying the damage-threshold/fail-safe approach to compression fatigue, tension/compression fatigue, and compression strength following low velocity impact.

Obrien, T. Kevin↗
NASA NTRS1990

Towards a damage tolerance philosophy for composite materials and structures

A damage-threshold/fail-safe approach is proposed to ensure that composite structures are both sufficiently durable for economy of operation, as well as adequately fail-safe or damage tolerant for flight safety. Matrix cracks are assumed to exist throughout the off-axis plies. Delamination onset is predicted using a strain energy release rate characterization. Delamination growth is accounted for in one of three ways: either analytically, using delamination growth laws in conjunction with strain energy release rate analyses incorporating delamination resistance curves; experimentally, using measured stiffness loss; or conservatively, assuming delamination onset corresponds to catastrophic delamination growth. Fail-safety is assessed by accounting for the accumulation of delaminations through the thickness. A tension fatigue life prediction for composite laminates is presented as a case study to illustrate how this approach may be implemented. Suggestions are made for applying the damage-threshold/fail-safe approach to compression fatigue, tension/compression fatigue, and compression strength following low velocity impact.

O'Brien, T. Kevin↗
NASA NTRS1997

Failure Study of Composite Materials by the Yeh-Stratton Criterion

The newly developed Yeh-Stratton (Y-S) Strength Criterion was used to study the failure of composite materials with central holes and normal cracks. To evaluate the interaction parameters for the Y-S failure theory, it is necessary to perform several biaxial loading tests. However, it is indisputable that the inhomogeneous and anisotropic nature of composite materials have made their own contribution to the complication of the biaxial testing problem. To avoid the difficulties of performing many biaxial tests and still consider the effects of the interaction term in the Y-S Criterion, a simple modification of the Y-S Criterion was developed. The preliminary predictions by the modified Y-S Criterion were relatively conservative compared to the testing data. Thus, the modified Y-S Criterion could be used as a design tool. To further understand the composite failure problem, an investigation of the damage zone in front of the crack tip coupled with the Y-S Criterion is imperative.

Yeh, Hsien-Yang↗
NASA NTRS1975

Impact response of graphite-epoxy flat laminates using projectiles that simulate aircraft engine encounters

An investigation of the response of a graphite-epoxy material to foreign object impact was made by impacting spherical projectiles of gelatin, ice, and steel normally on flat panels. The observed damage was classified as transverse (stress wave delamination and cracking), penetrative, or structural (gross failure): the minimum, or threshold, velocity to cause each class of damage was established as a function of projectile characteristics. Steel projectiles had the lowest transverse damage threshold, followed by gelatin and ice. Making use of the threshold velocities and assuming that the normal component of velocity produces the damage in nonnormal impacts, a set of impact angles and velocities was established for each projectile material which would result in damage to composite fan blades. Analysis of the operating parameters of a typical turbine fan blade shows that small steel projectiles are most likely to cause delamination and penetration damage to unprotected graphite-epoxy composite fan blades.

Preston, J. L., Jr.↗
NASA NTRS1995

Impact damage resistance and residual property assessment of (0/+/-45/90)s SCS-6/Timetal 21S

The impact damage resistance and residual mechanical properties of (0/ +/- 45/90)s SCS-6/Timetal 21S composites were evaluated. Both quasi-static indentation and drop-weight impact tests were used to investigate the impact behavior at two nominal energy levels (5.5 and 8.4 J) and determine the onset of internal damage. Through x-ray inspection, the extent of internal damage was characterized non-destructively. The composite strength and constant amplitude fatigue response were evaluated to assess the effects of the sustained damage. Scanning electron microscopy was used to characterize internal damage from impact in comparison to damage that occurs during mechanical loading alone. The effect of stacking sequence was examined by using specimens with the long dimension of the specimen both parallel (longitudinal) and perpendicular (transverse) to the 0 deg fiber direction. Damage in the form of longitudinal and transverse cracking occurred in all longitudinal specimens tested at energies greater than 6.3 J. Similar results occurred in the transverse specimens tested above 5.4 J. Initial load drop, characteristic of the onset of damage, occurred on average at 6.3 J in longitudinal specimens and at 5.0 J in transverse specimens. X-ray analysis showed broken fibers in the impacted region in specimens tested at the higher impact energies. At low impact energies, visible matrix cracking may occur, but broken fibers may not. Matrix cracking was noted along fiber swims and it appeared to depend on the surface quality of composite. At low impact energies, little damage has been incurred by the composite and the residual strength and residual life is not greatly reduced as compared to an undamaged composite. At higher impact energies, more damage occurred and a greater effect of the impact damage was observed.

Miller, Jennifer L.↗
NASA NTRS2009

Spacecraft Electrical Connector Selection and Application Processes

This assessment was initiated by the NASA Engineering & Safety Center (NESC) after a number of recent "high profile" connector problems, the most visible and publicized of these being the problem with the Space Shuttle's Engine Cut-Off System cryogenic feed-thru connector. The NESC commissioned a review of NASA's connector selection and application processes for space flight applications, including how lessons learned and past problem records are fed back into the processes to avoid recurring issues. Team members were primarily from the various NASA Centers and included connector and electrical parts specialists. The commissioned study was conducted on spacecraft connector selection and application processes at NASA Centers. The team also compared the NASA spacecraft connector selection and application process to the military process, identified recent high profile connector failures, and analyzed problem report data looking for trends and common occurrences. The team characterized NASA's connector problem experience into a list of top connector issues based on anecdotal evidence of a system's impact and commonality between Centers. These top issues are as follows, in no particular rank order: electrically shorted, bent and/or recessed contact pins, contact pin/socket contamination leading to electrically open or intermittencies, connector plating corrosion or corrosion of connector components, low or inadequate contact pin retention forces, contact crimp failures, unmated connectors and mis-wiring due to workmanship errors during installation or maintenance, loose connectors due to manufacturing defects such as wavy washer and worn bayonet retention, damaged connector elastomeric seals and cryogenic connector failure. A survey was also conducted of SAE Connector AE-8C1 committee members regarding their experience relative to the NASA concerns on connectors. The most common responses in order of occurrence were contact retention, plating issues, worn-out or damaged coupling mechanisms, bent pins, contact crimp barrel cracking and torn seals. In addition to these common themes, responses included issues with markings, dimensional errors on the build, contact/socket damage (handling), manufacturing defects and customer misapplication and mishandling. The NESC team concluded that considering the large quantity and wide variety of connectors successfully flown on human and robotic space applications, the number of failures is quite low. However, "high profile" failures with significant cost, schedule, safety, and/or mission success impacts continue to occur. It was also concluded that connector failures occur throughout a system's life-cycle with the majority of connector issues application related. A number of recommendations were identified for improving NASA connector selection processes and overall space connector reliability and performance.

Iannello, Chris↗