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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Response of Honeycomb Core Sandwich Panel with Minimum Gage GFRP Face-Sheets to Compression Loading After Impact

A compression after impact study has been conducted to determine the residual strength of three sandwich panel constructions with two types of thin glass fiber reinforced polymer face-sheets and two hexagonal honeycomb Nomex core densities. Impact testing is conducted to first determine the characteristics of damage resulting from various impact energy levels. Two modes of failure are found during compression after impact tests with the density of the core precipitating the failure mode present for a given specimen. A finite element analysis is presented for prediction of the residual compressive strength of the impacted specimens. The analysis includes progressive damage modeling in the face-sheets. Preliminary analysis results were similar to the experimental results; however, a higher fidelity core material model is expected to improve the correlation.

McQuigg, Thomas D.↗
NASA NTRSDate not supplied

Computational Assessment of the Opening Mode Facesheet-to-Core Fracture Toughness of a Thin-Gage Facesheet Sandwich Structure

The single-cantilevered beam test (SCB) is currently being considered for standardization for measuring the opening mode fracture toughness of sandwich structures subjected to facesheet-to-core separation. At present, the Area method is considered the benchmark method for determining energy required to propagate the crack. This method is problematic since it requires periodic unloading and cannot be evaluated instantaneously. Therefore, a method is needed to accurately and instantaneously calculate opening mode fracture toughness. In previous work, SCB tests with thin-gauge facesheets were performed to compare the J-integral approach to data reduction methods including the Modified Beam Theory (MBT) and the Area method. Large deviations (over 10%) in the calculated fracture toughness were observed between the J-integral and MBT for large displacements. In this study, a simulated SCB experiment using a virtual crackclosure technique was performed to assess the previously observed discrepancies. The predicted load displacement response, the predicted angle at the load application point, and the predicted crack growth results are in good agreement (within 5%) with the corresponding experimental data. Using the predicted load and angles, the predicted J-integral is in good agreement (within 10%) with the experimentally obtained solution. Using the MBT approach, the previously observed deviations in the fracture toughness were determined to be associated with the empirical extrapolation procedure to estimate the crack-root rotation correction from nonlinear compliance curves. The nonlinear compliance is determined to be associated with large displacement effects observed within the predicted and experimental results.

Sandwich Composite↗
NASA NTRS1992

High-temperature strain measurement techniques: Current developments and challenges

Since 1987, a very substantial amount of R&D has been conducted in an attempt to develop reliable strain sensors for the measurements of structural strains during ground testing and hypersonic flight, at temperatures up to at least 2000 deg F. Much of the effort has been focused on requirements of the NASP Program. This presentation is limited to the current sensor development work and characterization studies carried out within that program. It is basically an assessment as to where we are now and what remains to be done in the way of technical accomplishments to meet the technical challenges posed by the requirements and constraints established for the NASP Program. The approach for meeting those requirements and constraints has been multi-disciplinary in nature. It was recognized early on that no one sensor could meet all these requirements and constraints, largely because of the large temperature range (cryogenic to at least 2000 deg F) and many other factors, including the most challenging requirement that the sensor system be capable of obtaining valid 'first cycle data'. Present candidate alloys for resistance-type strain gages include Fe-Cr-Al and Pd-Cr. Although they have superior properties regarding withstanding very high temperatures, they exhibit large apparent strains that must either be accounted for or cancelled out by various techniques, including the use of a dual-element, half-bridge dummy gage, or electrical compensation networks. A significant effort is being devoted to developing, refining, and evaluating the effectiveness of those techniques over a broad range in temperature and time. In the quest to obtain first-cycle data, ways must be found to eliminate the need to prestabilize or precondition the strain gage, before it is attached to the test article. It should be noted that present NASP constraints do not permit prestabilization of the sensor, in situ. Gages are currently being 'heat treated' during manufacture in both the wire- and foil-type resistance strain gages, and evaluation is in progress. In addition, the 'gage-on-shim' concept is being revisited. That concept will permit heat treatment of the gage during manufacture, before attachment on the test article. Also, it may permit the individual calibration of each gage regarding gage factor and apparent strain. Candidate alloys for the NASP include titanium metal-matrix and carbon-carbon composites. Although those materials have very attractive properties at elevated temperatures in terms of strength and weight, they pose significant attachment problems. Methods for making reliable strain gage and thermocouple attachments to them are currently under development. Experience to date indicates that Rokide attachment of the sensor directly to the protective coating is easier than to the base material itself. However, interpreting strain data from gages attached in this way may prove difficult because of possible cracks in the coating that form 'islands' and the mobility of those 'islands'. It is concluded, therefore, that major technical challenges lie ahead as we proceed to meet the stringent strain sensor requirements and constraints of the NASP Program.

Lemcoe, M. M.↗
NASA NTRS1996

High-temperature Strain Sensor and Mounting Development

This report describes Government Work Package Task 29 (GWP29), whose purpose was to develop advanced strain gage technology in support of the National Aerospace Plane (NASP) Program. The focus was on advanced resistance strain gages with a temperature range from room temperature to 2000 F (1095 C) and on methods for reliably attaching these gages to the various materials anticipated for use in the NASP program. Because the NASP program required first-cycle data, the installed gages were not prestabilized or heat treated on the test coupons before first-cycle data were recorded. NASA Lewis Research Center, the lead center for GWP29, continued its development of the palladium-chromium gage; NASA Langley Research Center investigated a new concept gage using Kanthal A1; and the NASA Dryden Flight Research Center chose the well-known BCL-3 iron-chromium-aluminum gage. Each center then tested all three gages. The parameters investigated were apparent strain, drift strain, and gage factor as a function of temperature, plus gage size and survival rate over the test period. Although a significant effort was made to minimize the differences in test equipment between the three test sites (e.g., the same hardware and software were used for final data processing), the center employed different data acquisition systems and furnace configurations so that some inherent differences may be evident in the final results.

Williams, W. Dan↗
NASA NTRS2016

Forward Skirt Structural Testing on the Space Launch System (SLS) Program

Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the Space Launch System (SLS) program. One forward skirt is located in each solid rocket booster. Heritage forward skirts are aluminum 2219 welded structures. Loads are applied at the forward skirt thrust post and ball assembly. Testing was needed because SLS ascent loads are roughly 40% higher than Space Shuttle loads. Testing objectives were to determine margins of safety, demonstrate reliability, and validate analytical models. Two forward skirts were structurally tested using the test configuration. The test stand applied loads to the thrust post. Four hydraulic actuators were used to apply axial load and two hydraulic actuators were used to apply radial and tangential loads. The first test was referred to as FSTA-1 (Forward Skirt Structural Test Article) and was performed in April/May 2014. The purpose of FSTA-1 was to verify the ultimate capability of the forward skirt subjected to ascent ultimate loads. Testing consisted of two liftoff load cases taken to 100% limit load followed by an ascent load case taken to 110% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The second test was referred to as FSTA-2 and performed in July/August of 2014. The purpose of FSTA-2 was to verify the ultimate capability of the forward skirt subjected to liftoff ultimate loads. Testing consisted of six liftoff load cases taken to 100% limit load followed by the six liftoff cases taken to 140% limit load. Two ascent load cases were then tested to 100% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The forward skirts on FSTA-1 and FSTA-2 successfully carried all applied liftoff and ascent load cases. Both FSTA-1 and FSTA-2 were tested to failure by increasing the ascent loads. Failure occurred in the forward skirt thrust post radius. The forward skirts on FSTA-1 and FSTA-2 had nearly identical failure modes. FSTA-1 failed at 1.72 times limit load and FSTA-2 failed at 1.62 times limit load. This difference is primarily attributed to variation in material properties in the thrust post region. Test data were obtained from strain gages, deflection gages, ARAMIS digital strain measurement, acoustic emissions, and high-speed video. Strain gage data and ARAMIS strain were compared to finite element (FE) analysis predictions. Both the forward skirt and tooling were modeled. This allows the analysis to simulate the loading as close as possible to actual test configuration. FSTA-1 and FSTA-2 were instrumented with over 200 strain gages to ensure all possible failure modes could be captured. However, it turned out that three gages provided critical strain data. One was located in the post bore and two on the post radius. More gages were not specified due to space limitations and the desire to not interfere with the use of the ARAMIS system on the post radius. Measured strains were compared to analysis results for the load cycle to failure. Note that FSTA-1 gages were lost before failure was reached. FSTA-2 gages made it to the failure load but one of the radius gages was lost before testing began. This gage was not replaced because of the time and cost associated with disassembly of the test structure. Correlation to analysis was excellent for FSTA-1. FSTA-2 was not quite as good because there was more residual strain from previous load cycles. FSTA-2 was loaded and unloaded with 12 liftoff cases and two ascent cases before taking the skirt to failure. FSTA-1 only had two liftoff cases and one ascent case before taking the skirt to failure. The ARAMIS system was used to determine strain at the post radius by processing digital images of a speckled paint pattern. Digital cameras recorded images of the speckled paint pattern. ARAMIS strain results for FSTA-2 just prior to failure. Note a high strain location develops near the left side. This high strain compares well to analysis prediction for both FSTA-1 and FSTA-2. The strain at this location was also plotted versus limit load. Both FSTA-1 and FSTA-2 had excellent correlation between ARAMIS and analysis strains. Acoustic emission (AE) sensors were used to monitor for damage formation that may occur during testing (e.g., crack formation and growth or propagation). AE was very important because after disassembly of FSTA-1, a crack was observed in the ball fitting radius. The ball fitting did not crack on FSTA-2. AE data was used to reconstruct when the crack occurred. The AE energy versus time plot for FSTA. The energy increased considerably at 850 seconds (152% limit load), indicating a crack could have formed at this point. The only visual evidence found that could have corresponded to this was the crack that initiated in the ball fitting. The cracks in the forward skirt aluminum structures would likely have been lower energy due to a lower modulus and all that were found after failure correlated to occurring after the initial crack in the post radius. This was verified by high-speed cameras used to record the failure.

Lohrer, J. D.↗
NASA NTRS1990

Application of carbon-powder-polymer composite as a continuous crack-length sensor

This paper explores the application of carbon-powder-impregnated polymeric composites for measuring crack extensions. The strain sensitivity of the gage material is shown to be very small. In the first series of tests, the gage material is characterized by measuring the change in electrical resistance due to machined slits for various gage lengths. The measured responses is compared with the response predicted from a very simple electrical model. On the basis of good correlation and repeatability, the usefulness of such gages to measure crack extensions is assessed by a second series of tests. Further work to improve the gage response by optimizing the shape of the gage and making the gage and the adhesive layer thinner is proposed. The presented concept, with improvements, can result in a reliable, inexpensive crack gage requiring inexpensive instrumentation.

Prabhakaran, R.↗
NASA NTRS1992

Heat flux microsensor measurements and calibrations

A new thin-film heat flux gage has been fabricated specifically for severe high temperature operation using platinum and platinum-10 percent rhodium for the thermocouple elements. Radiation calibrations of this gage were performed at the AEDC facility over the available heat flux range (approx. 1.0 - 1,000 W/cu cm). The gage output was linear with heat flux with a slight increase in sensitivity with increasing surface temperature. Survivability of gages was demonstrated in quench tests from 500 C into liquid nitrogen. Successful operation of gages to surface temperatures of 750 C has been achieved. No additional cooling of the gages is required because the gages are always at the same temperature as the substrate material. A video of oxyacetylene flame tests with real-time heat flux and temperature output is available.

Terrell, James P.↗
NASA NTRS1998

Numerical Analysis of a Radiant Heat Flux Calibration System

A radiant heat flux gage calibration system exists in the Flight Loads Laboratory at NASA's Dryden Flight Research Center. This calibration system must be well understood if the heat flux gages calibrated in it are to provide useful data during radiant heating ground tests or flight tests of high speed aerospace vehicles. A part of the calibration system characterization process is to develop a numerical model of the flat plate heater element and heat flux gage, which will help identify errors due to convection, heater element erosion, and other factors. A 2-dimensional mathematical model of the gage-plate system has been developed to simulate the combined problem involving convection, radiation and mass loss by chemical reaction. A fourth order finite difference scheme is used to solve the steady state governing equations and determine the temperature distribution in the gage and plate, incident heat flux on the gage face, and flat plate erosion. Initial gage heat flux predictions from the model are found to be within 17% of experimental results.

Jiang, Shanjuan↗
NASA NTRS1973

Effect of specimen thickness of fatigue-crack-growth behavior and fracture toughness of 7075-T6 and 7178-T6 aluminum alloys

A study was made to determine the effects of specimen thickness on fatigue crack growth and fracture behavior of 7075-T6 and 7178-T6 aluminum alloy sheet and plate. Specimen thicknesses ranged from 5.1 to 12.7 mm (0.20 to 0.50 in.) for 7075-T6 and from 1.3 to 6.4 mm (0.05 to 0.25 in.) for 7178-T6. The stress ratios R used in the crack growth experiments were 0.02 and 0.50. For 7075-T6, specimen thickness had relatively little effect on fatigue-crack growth. However, the fracture toughness of the thickness of the thickest gage of 7075-T6 was about two-thirds of the fracture toughness of the thinner gages of 7075-T6. For 7178-T6, fatigue cracks generally grew somewhat faster in the thicker gages than in the thinnest gage. The fracture toughness of the thickest gage of 7178-T6 was about two-thirds of the fracture toughness of the thinner gages of 7178-T6. Stress intensity methods were used to analyze the experimental results. For a given thickness and value of R, the rate of fatigue crack growth was essentially a single-valued function of the stress intensity range for 7075-T6 and 7178-T6. An empirical equation developed by Forman, Kearney, and Engle fit the 7075-T6 and 7178-T6 crack growth data reasonably well.

Hudson, C. M.↗
NASA NTRS1985

National transonic facility Mach number system

The Mach number system for the Langley Research Center's National Transonic Facility was designed to measure pressures to determine Mach number to within + or - 0.002. Nine calibration laboratory type fused quartz gages, four different range gages for the total pressure measurement, and five different range gages for the static pressure measurement were used to satisfy the accuracy requirement over the 103,000-890,000 Pa total pressure range of the tunnel. The system which has been in operation for over 1 year is controlled by a programmable data process controller to select, through the operation of solenoid valves, the proper range fused quartz gage to maximize the measurement accuracy. The pressure gage's analog outputs are digitized by the process controller and transmitted to the main computer for Mach number computation. An automatic two-point on-line calibration of the nine quartz gages is provided using a high accuracy mercury manometer.

Kern, F. A.↗
NASA NTRS1957

Nonmetallic Material Compatibility with Liquid Fluorine

Static tests were made on the compatibility of liquid fluorine with several nonmetallic materials at -3200 F and at pressures of 0 and 1500 pounds per square inch gage. The results are compared with those from previous work with gaseous fluorine at the same pressures, but at atmospheric temperature. In general, although environmental effects were not always consistent, reactivity was least with the low-temperature, low-pressure liquid fluorine. Reactivity was greatest with the warm, high-pressure gaseous fluorine. None of the liquids and greases tested was found to be entirely suitable for use in fluorine systems. Polytrifluorochloroethylene and N-43, the formula for which is (C4F9)3N, did not react with liquid fluorine at atmospheric pressure or 1500 pounds per square inch gage under static conditions, but they did react when injected into liquid fluorine at 1500 pounds per square inch gage; they also reacted with gaseous fluorine at 1500 pounds per square inch gage. While water did not react with liquid fluorine at 1500 pounds per square inch gage, it is known to react violently with fluorine under other conditions. The pipe-thread lubricant Q-Seal did not react with liquid fluorine, but did react with gaseous fluorine at 1500 pounds per square inch gage. Of the solids, ruby (Al2O3) and Teflon did not react under the test conditions. The results show that the compatibility of fluorine with nonmetals depends on the state of the fluorine and the system design.

Price, Harold G , Jr↗
NASA NTRS1991

An Evaluation of the Iosipescu Specimen for Composite Materials Shear Property Measurement

A detailed evaluation of the suitability of the Iosipescu specimen tested in the modified Wyoming fixture is presented. An experimental investigation using conventional strain gage instrumentation and moire interferometry is performed. A finite element analysis of the Iosipescu shear test for unidirectional and cross-ply composites is used to assess the uniformity of the shear stress field in the vicinity of the notch, and demonstrate the effect of the nonuniform stress field upon the strain gage measurements used for the determination of composite shear moduli. From the test results for graphite-epoxy laminates, it is shown that the proximity of the load introduction point to the test section greatly influences the individual gage readings for certain fiber orientations but the effect upon shear modulus measurement is relatively unimportant. A numerical study of the load contact effect shows the sensitivity of some fiber configurations to the specimen/fixture contact mechanism and may account for the variations in the measured shear moduli. A comparison of the strain gage readings from one surface of a specimen with corresponding data from moire interferometry on the opposite face documented an extreme sensitivity of some fiber orientations to eccentric loading which induced twisting and yielded spurious shear stress-strain curves. In the numerical analysis, it is shown that the Iosipescu specimens for different fiber orientations have to be modeled differently in order to closely approximate the true loading conditions. Correction factors are needed to allow for the nonuniformity of the strain field and the use of the average shear stress in the shear modulus evaluation. The correction factors, which are determined for the region occupied by the strain gage rosette, are found to be dependent upon the material orthotropic ratio and the finite element models. Based upon the experimental and numerical results, recommendations for improving the reliability and accuracy of the shear modulus values are made, and the implications for shear strength measurement discussed. Further application of the Iosipescu shear test to woven fabric composites is presented. The limitations of the traditional strain gage instrumentation on the satin weave and high tow plain weave fabrics is discussed. Test results of a epoxy based aluminum particulate composite is also presented. A modification of the Iosipescu specimen is proposed and investigated experimentally and numerically. It is shown that the proposed new specimen design provides a more uniform shear stress field in the test section and greatly reduces the normal and shear stress concentrations in the vicinity of the notches. While the fabrication and the material cost of the proposed specimen is tremendously reduced, it is shown the accuracy of the shear modulus measurement is not sacrificed.

Ho, Henjen↗
NASA NTRS2019

Application of a Temperature-Dependent Load Prediction Method to a RUAG Six-Component Block-Type Balance

Temperature-dependent data of a RUAG six-component block-type balance was analyzed to assess the accuracy of two load prediction methods for temperature-dependent balance data. The supplied data was prepared for the analysis by splitting it into calibration and check load data subsets. The first calibration data subset was obtained at a temperature of 294 Kelvin. The second calibration data subset was obtained at a temperature of 315 Kelvin. A subset of 38 points was extracted from the second data set and used as check loads so that the accuracy of the two load prediction methods could be tested. First, the Iterative Method in combination with an extended independent and dependent variable set was used for the balance load prediction. This approach fits electrical outputs as a function of loads and the temperature and, afterwards, constructs a load iteration scheme from the regression coefficients so that loads can be predicted from outputs and the temperature during a wind tunnel test. The Non-Iterative Method was also used for the load prediction. This alternate method can more easily be implemented in a data system as loads are directly fitted as a function of electrical outputs and the temperature. Analysis results for the axial force are only discussed in the paper as similar results were obtained for the other five load components. Results for both methods clearly show that the cross-product term constructed from either a primary gage load or a primary gage output and the temperature explains the majority of the temperature-dependent part of the predicted balance load. This term models the temperature dependent nature of the gage sensitivity. Therefore, it is recommended to apply primary gage loadings at different temperatures during a balance calibration whenever temperature effects need to be described. These loadings will contain information about the temperature-dependent nature of the gage sensitivities that can be quantified by related cross-product terms in regression models of the data.

strain-gage balance↗
NASA NTRS1990

Igniter adapter-to-igniter chamber deflection test

Testing was performed to determine the maximum RSRM igniter adapter-to-igniter chamber joint deflection at the crown of the inner joint primary seal. The deflection data was gathered to support igniter inner joint gasket resiliency predictions which led to launch commit criteria temperature determinations. The proximity (deflection) gage holes for the first test (Test No. 1) were incorrectly located; therefore, the test was declared a non-test. Prior to Test No. 2, test article configuration was modified with the correct proximity gage locations. Deflection data were successfully acquired during Test No. 2. However, the proximity gage deflection measurements were adversely affected by temperature increases. Deflections measured after the temperature rise at the proximity gages were considered unreliable. An analysis was performed to predict the maximum deflections based on the reliable data measured before the detectable temperature rise. Deflections to the primary seal crown location were adjusted to correspond to the time of maximum expected operating pressure (2,159 psi) to account for proximity gage bias, and to account for maximum attach and special bolt relaxation. The maximum joint deflection for the igniter inner joint at the crown of the primary seal, accounting for all significant correction factors, was 0.0031 in. (3.1 mil). Since the predicted (0.003 in.) and tested maximum deflection values were sufficiently close, the launch commit criteria was not changed as a result of this test. Data from this test should be used to determine if the igniter inner joint gasket seals are capable of maintaining sealing capability at a joint displacement of (1.4) x (0.0031 in.) = 0.00434 inches. Additional testing should be performed to increase the database on igniter deflections and address launch commit criteria temperatures.

Cook, M.↗
NASA NTRS1992

Strain sensing technology for high temperature applications

This review paper discusses the status of strain sensing technology for high temperature applications. Technologies covered are those supported by NASA such as required for applications in hypersonic vehicles and engines, advanced subsonic engines, as well as material and structure development. The applications may be at temperatures of 540 C (1000 F) to temperatures in excess of 1400 C (2500 F). The most promising technologies at present are the resistance strain gage and remote sensing schemes. Resistance strain gages discussed include the BCL gage, the LaRC compensated gage, and the PdCr gage. Remote sensing schemes such as laser based speckle strain measurement, phase-shifting interferometry and X-ray extensometry will be discussed. Present status and limitations of these technologies are presented.

Williams, W. D.↗