Some modifications of simple descriptions of yielding at crack tips
Modifications of simple descriptions of yielding at crack tips
ELASTIC PLATE↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Origin of the elastic limit of body-centered cubic metals at low temperature
Origin of low-temperature macroscopic elastic limit of body-centered cubic metals
METAL↗
Yielding and brittle cracking of an orthotropic strip.
Yielding and brittle cracking of orthotropic strip, using Wiener-Hopf technique and asymptotic method for isotropic case
WIENER-HOPF EQUATION↗
Applications of gap welding
Gap welding of electronic interconnections yields high strength joints, is easy to use, and allows visual inspection of the welding process. It is easily adaptable to automated circuit assembly.
Adams, G. D.↗
Method of making an explosively welded scarf joint
A method is presented for obtaining a bond joint between thin metal members without the addition of a bonding agent. The method yields bond strengths comparable to the parent metal. The method comprises overlapping the materials at the edges and bonding them by explosive welding while also making use of the explosive force to shape the materials into an essentially planar configuration.
Bement, L. J.↗
Winding for the wind
The mechanical properties and construction of epoxy-impregnated fiber-glass blades for wind turbines are discussed, along with descriptions of blades for the Mod 0A and Mod 5A WECS and design goals for a 4 kW WECS. Multicell structure combined with transverse filament tape winding reduces labor and material costs, while placing a high percentage of 0 deg fibers spanwise in the blades yields improved strength and elastic properties. The longitudinal, transverse, and shear modulus are shown to resist stresses exceeding the 50 lb/sq ft requirements, with constant stress resistance expected until fatigue failure is approached. Regression analysis indicates a fatigue life of 400 million operating cycles. The small WECS under prototype development features composite blades, nacelle, and tower. Rated at 5.7 kW in a 15 mph wind, the machine operates over a speed range of 9-53.9 mph and is expected to produce 16,200 kWh annually in a 10 mph average wind measured at 30 ft.
Weingart, O.↗
Thermal infrared lines of methane broadened by nitrogen at low temperatures
Measurements of spectral transmittance in the nu4-fundamental band of (C-12)H4 have been performed at low temperatures using a Fourier transform spectrometer with apodized spectral resolution of 0.06 per cm. With applications to lines formed in the atmospheres of Titan and earth in mind, N2 has been used as the broadening gas. Comparisons of observed and computed spectral transmittances on a line-by-line basis have yielded line strengths, N2-broadened half-widths and their variation with temperature. Best agreement between measured and computed spectra was obtained when the absolute intensity of the band was taken as 128 per (sq cm-atm) at 296 K. Line widths were found to vary as T to the n power with n = -1.0 for lines of the F-species and 0.63 for the A-species. The measured line widths are considerably larger than those used in the AFGL compilation.
Varanasi, P.↗
Intensity measurements in the nu4-fundamental of (C-13)H4 at planetary atmospheric temperatures
Measurements of spectral transmittance have been performed in the nu4-fundamental band of (C-13)H4 at low temperatures of planetary atmospheric interest with spectral resolution of 0.06 per cm. Comparison of observed and computed spectral transmittance on a line-by-line basis has yielded line strengths. Best agreement between measured and computed spectra was obtained when the absolute intensity of the band was taken as 123 per (sq cm atm) at 296 K.
Varanasi, P.↗
The structure of ion plated films in relation to coating properties
Ion plating is an ion assisted or glow discharge deposition technique, where ions or energetic atoms transfer energy, momentum and charge to the substrate and the growing film in a manner which can be controlled to favorably modify surface, subsurface chemistry, and microstructure. The glow discharge energizing effects from the initial nucleation stages to the final film growth are discussed. As a result, adherence, coherence, internal stresses, density and morphology of the coatings are significantly improved, over the conventional (nonion-assisted) techniques which in turn favorably affect the surface initiated failures caused by friction, wear, erosion, corrosion and fatigue. Ion plated films because of their graded coating/substrate interface, fine, uniform, densely packed film structure also induce a surface strengthening effect which improved the mechanical properties such as yield, tensile strength and fatigue life. Since a uniform, continuous film can be obtained at lower nominal film thickness, this effect is of great importance in solid film lubrication and in corrosion protection.
Spalvins, T.↗
Solid state processing for high temperature alloys and composites
A variety of solid state powder processing methods have been examined for their potential to produce high temperature materials. These techniques included solid state diffusion, mechanical alloying, reaction milling, and exothermic reactions. While both mechanical alloying and exothermic reactions are capable of producing high temperature composites in addition to yielding solid solution and precipitation hardened alloys, reaction milling can only be used to make composite materials. Although at present this method has only been applied to make carbide strengthened Al, recent work indicates that reaction milling is capable of yielding high strength NiAl-AlN composites.
Whittenberger, J. Daniel↗
A low cost method of testing compression-after-impact strength of composite laminates
A method was devised to test the compression strength of composite laminate specimens that are much thinner and wider than other tests require. The specimen can be up to 7.62 cm (3 in) wide and as thin as 1.02 mm (.04 in). The best features of the Illinois Institute of Technology Research Institute (IITRI) fixture are combined with an antibuckling jig developed and used at the University of Dayton Research Institute to obtain a method of compression testing thin, wide test coupons on any 20 kip (or larger) loading frame. Up to 83 pct. less composite material is needed for the test coupons compared to the most commonly used compression-after-impact (CAI) tests, which calls for 48 ply thick (approx. 6.12 mm) test coupons. Another advantage of the new method is that composite coupons of the exact lay-up and thickness of production parts can be tested for CAI strength, thus yielding more meaningful results. This new method was used to compression test 8 and 16 ply laminates of T300/934 carbon/epoxy. These results were compared to those obtained using ASTM standard D 3410-87 (Celanese compression test). CAI testing was performed on IM6/3501-6, IM7/SP500 and IM7/F3900. The new test method and associated fixture work well and is a valuable asset to MSFC's damage tolerance program.
Nettles, Alan T.↗
Very high spatial resolution two-dimensional solar spectroscopy with video CCDs
We have developed techniques for recording and reducing spectra of solar fine structure with complete coverage of two-dimensional areas at very high spatial resolution and with a minimum of seeing-induced distortions. These new techniques permit one, for the first time, to place the quantitative measures of atmospheric structure that are afforded only by detailed spectral measurements into their proper context. The techniques comprise the simultaneous acquisition of digital spectra and slit-jaw images at video rates as the solar scene sweeps rapidly by the spectrograph slit. During data processing the slit-jaw images are used to monitor rigid and differential image motion during the scan, allowing measured spectrum properties to be remapped spatially. The resulting quality of maps of measured properties from the spectra is close to that of the best filtergrams. We present the techniques and show maps from scans over pores and small sunspots obtained at a resolution approaching 1/3 arcsec in the spectral region of the magnetically sensitive Fe I lines at 630.15 and 630.25 nm. The maps shown are of continuum intensity and calibrated Doppler velocity. More extensive spectral inversion of these spectra to yield the strength of the magnetic field and other parameters is now underway, and the results of that analysis will be presented in a following paper.
Johanneson, A.↗
Standard Methods for Bolt-Bearing Testing of Textile Composites
The response of three 2-D braided materials to bolt bearing loading was evaluated using data generated by Boeing Defense and Space Group in Philadelphia, PA. Three test methods, stabilized single shear, unstabilized single shear, and double shear, were compared. In general, these textile composites were found to be sensitive to bolt bearing test methods. The stabilized single shear method yielded higher strengths than the unstabilized single shear method in all cases. The double shear test method always produced the highest strengths but these results may be somewhat misleading. It is therefore recommended that standard material comparisons be made using the stabilized single shear test method. The effects of two geometric parameters, W/D and e/D, were also studied. An evaluation of the effect of the specimen width (W) to hole diameter (D) ratio concluded that bolt bearing responses were consistent with open hole tension results. A W/D ratio of 6 or greater should be maintained. The proximity of the hole to the specimen edge significantly affected strength. In all cases, strength was improved by increasing the ratio of the distance from the hole center to the specimen edge (e) to the hole diameter (D) above 2. An e/D ratio of 3 or greater is recommended.
Portanova, M. A.↗
Statistical Comparison and Improvement of Methods for Combining Random and Harmonic Loads
Structures in many environments experience both random and harmonic excitation. A variety of closed-form techniques has been used in the aerospace industry to combine the loads resulting from the two sources. The resulting combined loads are then used to design for both yield ultimate strength and high cycle fatigue capability. This paper examines the cumulative distribution function (CDF) percentiles obtained using each method by integrating the joint probability density function of the sine and random components. A new Microsoft Excel spreadsheet macro that links with the software program Mathematics is then used to calculate the combined value corresponding to any desired percentile along with a curve fit to this value. Another Excel macro is used to calculate the combination using a Monte Carlo simulation. Unlike the traditional techniques, these methods quantify the calculated load value with a Consistent percentile. Using either of the presented methods can be extremely valuable in probabilistic design, which requires a statistical characterization of the loading. Also, since the CDF at high probability levels is very flat, the design value is extremely sensitive to the predetermined percentile; therefore, applying the new techniques can lower the design loading substantially without losing any of the identified structural reliability.
Brown, Andrew M.↗
Nitrile/Buna N Material Failure Assessment for an O-Ring used on the Gaseous Hydrogen Flow Control Valve (FCV) of the Space Shuttle Main Engine
After the rollout of Space Shuttle Discovery in April 2005 in preparation for return-to-flight, there was a failure of the Orbiter (OV-103) helium signature leak test in the gaseous hydrogen (GH2) system. Leakage was attributed to the Flow Control Valve (FCV) in Main Engine 3. The FCV determined to be the source of the leak for OV-103 is designated as LV-58. The nitrile/Buna N rubber O-ring seal was removed from LV-58, and failure analysis indicated radial cracks providing leak paths in one quadrant. Cracks were eventually found in 6 of 9 FCV O-rings among the three Shuttle Orbiters, though none were as severe as those for LV-58, OV-103. Testing by EM10 at MSFC on all 9 FCV O- rings included: laser dimensional, Shore A hardness and properties from a dynamic mechanical analyzer (DMA) and an Instron tensile machine. The following test data was obtained on the cracked quadrant of the LV-58, OV-103 O-ring: (1) the estimated compression set was only 9.5%, compared to none for the rest of the O-ring; (2) Shore A hardness for the O.D. was higher by almost 4 durometer points than for the rest of the O-ring; and (3) DMA data showed that the storage/elastic modulus E was almost 25% lower than for the rest of the O-ring. Of the 8 FCV O-rings tested on an Instron, 4 yielded tensile strengths that were below the MIL spec requirement of 1350 psi-a likely influence of rubber cracking. Comparisons were made between values of modulus determined by DNA (elastic) and Instron (Young s). Each nitrile/Buna N O-ring used in the FCV conforms to the MIL-P-25732C specification. A number of such O-rings taken from shelf storage at MSFC and Kennedy Space Center (KSC) were used to generate a reference curve of DMA glass transition temperature (Tg) vs. shelf storage time ranging from 8 to 26 years. A similar reference curve of TGA onset temperature (of rubber weight loss) vs. shelf storage time was also generated. The DMA and TGA data for the used FCV O-rings were compared to the reference curves. Correlations were also made between the DMA modulus (at 22 C) and Shore A hardness for all 9 of the FCV O-rings used among the three Shuttle Orbiters. The radial cracking in the FCV O-rings was determined to be due to ozone attack, as nitrile/Buna N rubber is susceptible to such attack. Nitrile/Buna N material under MIL-P25732C should be used in a hydraulic fluid environment to help protect it from cracking. However, the FCV O-rings were used in an air only environment. The FCV design has as much as a 9-mil gap that allows the O.D. of the O-ring to be directly exposed to ozone, pressurized air and some elevated temperatures, accelerating the weathering process that leads to O-ring cracking. Space Shuttle flights will likely not continue past 2010. Therefore, Shuttle management decided to continue using the nitrile/Buna N material for the FCVs, but have each O-ring replaced after 3 years to minimize any chances for crack initiation.
Wingard, Doug↗
Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields
Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.
additive manufacturing↗
Influence of Specimen Preparation and Specimen Size on Composite Transverse Tensile Strength and Scatter
The influence of specimen polishing, configuration, and size on the transverse tension strength of two glass-epoxy materials, and one carbon-epoxy material, loaded in three and four point bending was evaluated. Polishing machined edges, arid/or tension side failure surfaces, was detrimental to specimen strength characterization instead of yielding a higher, more accurate, strength as a result of removing inherent manufacture and handling flaws. Transverse tension strength was typically lower for longer span lengths due to the classical weakest link effect. However, strength was less sensitive to volume changes achieved by increasing specimen width. The Weibull scaling law typically over-predicted changes in transverse tension strengths in three point bend tests and under-predicted changes in transverse tension strengths in four point bend tests. Furthermore, the Weibull slope varied with specimen configuration, volume, and sample size. Hence, this scaling law was not adequate for predicting transverse tension strength of heterogeneous, fiber-reinforced, polymer matrix composites.
OBrien, T. Kevin↗
Influence of Specimen Preparation and Specimen Size on the Transverse Tensile Strength and Scatter of Glass Epoxy Laminates
The influence of specimen polishing, specimen configuration, and specimen size on the transverse tension strength of two glass epoxy materials loaded in three and four point bending was evaluated. Polishing machined edges, and/or tension side failure surfaces, was detrimental to specimen strength characterization instead of yielding a higher, more accurate, strength as a result of removing inherent manufacture and handling flaws. Transverse tension strength was sensitive to span length due to the classical weakest link effect. However, strength was less sensitive to volume changes achieved by increasing specimen width. The Weibull scaling law over-predicted changes in transverse tension strengths in three point bend tests and under-predicted changes in transverse tension strengths in four point bend tests. Furthermore, the Weibull slope varied with specimen configuration, volume, and sample size. Hence, the utility of this scaling law for predicting transverse tension strength is unclear.
OBrien, T. Kevin↗