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Load-transfer capacities and resistances to fatigue increased. Series of high-strength bonded-stud designs developed for joining laminated wood to metal. Test results for bonded-stud designs demonstrated joint strengths approaching 10,000 to 12,000 psi (69 to 83 MPa) in ultimate strength and 5,000 psi (34 MPa) in high cycle fatigue strength of wood/epoxy composite achieved.
As a result of high localized plastic deformation experienced during proof testing in an International Space Station connecting module, a study was undertaken to determine the deformation response of a 2219-T851 roll forging. After prestraining 2219-T851 Al specimens to simulate strains observed during the proof testing, creep tests were conducted in the temperature range from ambient temperature to 107 C (225 F) at stress levels approaching the ultimate tensile strength of 2219-T851 Al. Strain-time histories and strain rate responses were examined. The strain rate response was extremely high initially, but decayed rapidly, spanning as much as five orders of magnitude during primary creep. Select specimens were subjected to incremental step loading and exhibited initial creep rates of similar magnitude for each load step. Although the creep rates decreased quickly at all loads, the creep rates dropped faster and reached lower strain rate levels for lower applied loads. The initial creep rate and creep rate decay associated with primary creep were similar for specimens with and without prestrain; however, prestraining (strain hardening) the specimens, as in the aforementioned proof test, resulted in significantly longer creep life.
This paper describes the pre-flight stage separation analysis that was conducted in support of the final flight of the X-43A. In that flight, which occurred less than eight months after the successful Mach 7 flight, the X-43A Research Vehicle attained a peak speed of Mach 9.6. Details are provided on how the lessons learned from the Mach 7 flight affected separation modeling and how adjustments were made to account for the increased flight Mach number. Also, the procedure for defining the feedback loop closure and feed-forward parameters employed in the separation control logic are described, and their effect on separation performance is explained. In addition, the range and nominal values of these parameters, which were included in the Mission Data Load, are presented. Once updates were made, the nominal pre-flight trajectory and Monte Carlo statistical results were determined and stress tests were performed to ensure system robustness. During flight the vehicle performed within the uncertainty bounds predicted in the pre-flight analysis and ultimately set the world record for airbreathing powered flight.
The Urban Air Mobility Side-by-Side Test Stand (SBS) is a new capability for the National Aeronautics and Space Administration (NASA) to test the conceptual side-by-side rotorcraft configuration. This test stand enhances the experimental capabilities of the Revolutionary Vertical Lift Technology (RVLT) Project and is primarily designed to be tested in the U.S. Army’s 7-by 10-Foot Wind Tunnel at NASA Ames Research Center. One of the goals for the SBS is to identify the optimal degree of rotor overlap that will yield the best aerodynamic performance. The SBS has two counter-rotating, intermeshing rotors that can vary in lateral separation. The test stand can pitch nose up and nose down, with each rotor having the capability to be trimmed independently through cyclic and collective controls. Six-axis load cells and rotary torque sensors are placed underneath each rotor to measure the thrust, torque, and side force from each rotor system. This paper describes the mechanical design of the SBS and outlines the structural analyses conducted to ensure a safety factor of 4 for ultimate strength and 3 for yield strength during all experimental testing.
Corrosion is considered a uniform thickness reduction design guideline of the maritime industry. However, additionally, the corroded and irregular morphology of the surface affects the steel's load-bearing capacity and its impact on the strength and elongation behaviour of the steel is not yet fully understood. These effects on the local behaviour of steel structures under tensile loading were investigated with tensile tests on naturally corroded steel specimens and nonlinear finite element simulations including the corroded surface morphology with a uniform surface idealation. The models also include the deformed specimen shape. The developed approach led to highly accurate parametric finite element models predicting the ultimate tensile strength and longitudinal position of fracture. The results show that all included aspects are essential for accurate simulations, while solely the maximum available surface resolution was not as decisive.
Results are presented for a study intended to summarize lifetime data on several fiber/epoxy composite materials subjected to sustained uniaxial tensile loading, to report preliminary results of an accelerated test method for predicting the life of simple composites, and to describe related work in progress on pressure vessels and other filament-wound structures. The lifetime performance of the tested composites was compared by plotting the percent of ultimate strength (applied fiber stress normalized with respect to fiber failure stress in a composite) versus lifetime. In terms of performance in long-term tensile applications, the tested composites are ranked in the following order: graphite/epoxy, Be wire/epoxy, Aramid/epoxy, and S-glass/epoxy. The accelerated test using temperature and stress to simulate the passage of time proves to be encouraging, at least in the case of the Aramid/epoxy composite. The potential of a statistical analysis based on Weibull distribution analyses or a power law relationship is demonstrated.
Graphite-epoxy floor sections representative of aircraft fuselage construction were statically and dynamically tested to evaluate their response to crash loadings. These floor sections were fabricated using a frame-stringer design typical of present aluminum aircraft without features to enhance crashworthiness. The floor sections were tested as part of a systematic research program developed to study the impact response of composite components of increasing complexity. The ultimate goal of the research program is to develop crashworthy design features for future composite aircraft. Initially, individual frames of six-foot diameter were tested both statically and dynamically. The frames were then used to construct built-up floor sections for dynamic tests at impact velocities of approximately 20 feet/sec to simulate survivable crash velocities. In addition, static tests were conducted to gain a better understanding of the failure mechanisms seen in the dynamic tests.
The programming and algorithms needed for implementing a full-field, 3-D velocimeter for laminar flow systems and the appropriate hardware to fully implement this ultimate system are discussed. It appears that imaging using a synched pair of video cameras and digitizer boards with synched rails for camera motion will provide a viable solution to the laminar tracking problem. The algorithms given here are simple, which should speed processing. On a heavily loaded VAXstation 3100 the particle identification can take 15 to 30 seconds, with the tracking taking less than one second. It seeems reasonable to assume that four image pairs can thus be acquired and analyzed in under one minute.
The concept of the Coordinated Data Analysis Workshop (CDAW) grew out of the International Magnetospheric Study (IMS) program. According to this concept, data are to be pooled from a wide variety of spacecraft and ground-based sources for limited time intervals. These data are to provide the basis for the performance of very detailed correlative analyses, usually with fairly limited physical problems in mind. However, in the case of the CDAW 6 truly global goals are involved. The primary goal is to trace the flow of energy from the solar wind through the magnetosphere to its ultimate dissipation by substorm processes. The present investigation has the specific goal to examine the evidence for the storage of solar wind energy in the magnetotail prior to substorm expansion phase onsets. Of particular interest is the determination, in individual substorm cases, of the time delays between the loading of energy into the magnetospheric system and the subsequent unloading of this energy.
An integrated two-dimensional finite element was developed to calculate interlaminar stresses and strain energy release rates for the study of delamination in composite laminates subjected to uniaxial tension, bending, and torsion loads. Addressed are the formulation, implementation, and verification of the model. Parametric studies were conducted on the effect of Poisson's ratio mismatch between plies and the stacking sequence on interlaminar stress, and on the effect of delamination opening height and delamination length, due to bending, on strain energy release rate for various laminates. A comparison of strain energy release rates in all-graphite and graphite/glass hybrid laminates is included. The preliminary results of laminates subjected to torsion are also included. Fatigue tension tests were conducted on Mode 1 and mixed mode edge-delamination coupons to establish the relationship between fatigue load vs. onset of delamination cycle. The effect on the fatigue delamination onset of different frequencies (1 and 5 Hz) was investigated for glass, graphite,and their hybrid laminates. Although a 20 percent increase in the static onset-of-delamination strength and a 10 percent increase in ultimate strength resulted from hybridizing the all-graphite laminate with a 90 deg glass ply, the fatigue onset is lower in the hybrid laminate than in the all-graphite laminate.
It is well known that failure of a material is a locally driven event. In the case of ceramic matrix composites (CMCs), significant variations in the microstructure of the composite exist and their significance on both deformation and life response need to be assessed. Examples of these variations include changes in the fiber tow shape, tow shifting/nesting and voids within and between tows. In the present work, the influence of scale specific architectural features of woven ceramic composite are examined stochastically at both the macroscale (woven repeating unit cell (RUC)) and structural scale (idealized using multiple RUCs). The recently developed MultiScale Generalized Method of Cells methodology is used to determine the overall deformation response, proportional elastic limit (first matrix cracking), and failure under tensile loading conditions and associated probability distribution functions. Prior results showed that the most critical architectural parameter to account for is weave void shape and content with other parameters being less in severity. Current results show that statistically only the post-elastic limit region (secondary hardening modulus and ultimate tensile strength) is impacted by local uncertainties both at the macro and structural level.
This report describes an experimental investigation of the secondary flow within and aft of an axial compressor model with thick endwall boundary layers. The objective of the study was to obtain detailed aerodynamic and trace gas concentration traverse data aft of a well documented isolated rotor for the ultimate purpose of improving the design phases of compressor development based on an improved physical understanding of secondary flow. It was determined from the flow visualization, aerodynamic, and trace gas concentration results that the relative unloading of the midspan region of the airfoil inhibitied a fullspan separation at high loading preventing the massive radial displacement of the hub corner stall to the tip. Radial distribution of high and low total pressure fluid influenced the magnitude of the spanwise distribution of loss, such that, there was a general decreases in loss near the hub to the extent that for the least loaded case a negative loss (increase in total pressure) was observed. The ability to determine the spanwise distribution of blockage was demonstrated. Large blockage was present in the endwall regions due to the corner stall and tip leakage with little blockage in the core flow region. Hub blockage was found to increase rapidly with loading.
The effects of thermal and pressure cycling on the fatigue performance of carbon-carbon composites, and the influence of mission cycling on these effects, were investigated by subjecting both virgin and mission-cycled two-dimensional specimens of SiC-coated carbon-carbon composites to fatigue tests, conducted at room temperature in three-point bending, with a stress ratio of 0.2 and a frequency of 1 Hz. It was found that the fatigue strength of C-C composites is high (about 90 percent of the ultimate flexural strength), but decreased with the mission cycling. The lowering of the fatigue strength with mission cycling is attributed to the increase in interfacial bond strength due to thermal and pressure cycling of the material. The already high sensitivity of C-C composites to stress during cyclic loading increases further with the amount of mission cycling. Results of NDE suggest that the damage growth in virgin C-C, in the high-cycle range, is slow at the initial stage of the cyclic life, but propagates rapidly after certain threshold cycles of the fatigue life.
Capturing carbon dioxide (CO2) from post-combustion gas streams is an energy-intensive process that is required prior to either converting or sequestering CO2. There are a few commercial offerings of 1st and 2nd generation aqueous amine technologies, however the cost of capturing CO2 with these technologies remains high. To decrease costs of capture, researchers are designing efficient solvent systems with the goal of being drop-in replacements for 1st and 2nd generation infrastructure. One approach has seen the development of water-lean solvents that aim to increase efficiency by reducing the water content in solution. Water-lean solvents such as GE’s GAP/TEG are promising technologies, with potential to halve the parasitic load to a coal-fired power plant, only if the intrinsically high solution viscosities and hydrolysis of the siloxane moieties could be mitigated. We present here, an integrated multidisciplinary approach to overhaul the GAP/TEG solvent system at the molecular level to mitigate hydrolysis while also reducing viscosity. We present molecular-level insights into chemical speciation of CO2-containing ions, showing that co-solvents and diluents have a negligible effect on reducing viscosity and are not needed. This finding allowed for the design of singlecomponent siloxane-free diamine derivatives with site-specific incorporation of selective chemical moieties for direct placement and orientation of hydrogen bonding to reduce viscosity. Ultimately, we present new single-component diamine formulations less susceptible to hydrolysis that exhibit up to a 98% reduction in viscosity compared to the initial GAP/TEG formulation.
In order to evaluate the viability of ShAPE processed Mg alloys as a feedstock for fabricating lightweight sheet material, tubes consisting of ShAPE-extruded Mg alloy ZK60 were flattened into plates and hot rolled at 450 °C to reductions of 37%, 68%, and 93%. The mechanical properties and microstructure of the rolled material were characterized through tensile testing and electron backscattered diffraction (EBSD). ZK60 specimens rolled to 68% reduction had tensile properties similar to published properties of rolled ZK60 sheets fabricated using conventional processes, and exhibited negligible tensile anisotropy referenced to the rolling direction. Additional rolling from 68% to 93% reduced the ultimate tensile stress in the rolling direction from 341.74±5.96 MPa to 260.76±22.4MPa. The yield stress and elongation to failure of the material also decreased from 292.16±1.11 MPa to 256.93±18.4 MPa and 6.95±1.94% to 3.38±0.51%, respectively, but negligible little anisotropy was observed with respect to loading direction. EBSD mapping indicated that the as-extruded ZK60 had texture rotated away from the basal direction which developed into a strong basal texture over numerous hot rolling steps. This evolution in texture has been observed after rolling for hot-rolled ZK60 fabricated through conventional extrusion processes. The initial grain structure was found to have experienced noticeable twinning from flattening the tube into plate. After hot rolling, the grain structure became more equiaxed, but the average grain diameter did not change appreciably from 5.15 ± 3.39 µm in the ShAPE extruded material, to 5.27 ± 12.44 µm in the 93% hot rolled sheet. This response to hot rolling is similar to the response of ZK60 fabricated using other methods such as Equal Channel Angular Processing (ECAP). Therefore, this work demonstrates ShAPE has the potential as an alternative method to producing feedstock for Mg alloy sheets. Modifications to the experimental procedure which could lead to improvements in observed properties are briefly discussed.
The facility Hazardous Gas Detection System (HGDS) at Kennedy Space Center (KSC) is a mass spectrometer based gas analyzer. Two instruments make up the HGDS, which is installed in a prime/backup arrangement, with the option of using both analyzers on the same sample line, or on two different lines simultaneously. It is used for monitoring the Shuttle during fuel loading, countdown, and drainback, if necessary. The use of complex instruments, operated over many shifts, has caused problems in tracking the status of the ground support equipment (GSE) and the vehicle. A requirement for overall system reliability has been a major force in the development of Shuttle GSE, and is the ultimate driver in the choice to pursue artificial intelligence (AI) techniques for Shuttle and Advanced Launch System (ALS) mass spectrometer systems. Shuttle applications of AI are detailed.
The results are presented of an analytic and experimental research program involving a Sikorsky S-55 helicopter tail cone directed ultimately to the improved structural analysis of airframe substructures typical of moderate sized helicopters of metal semimonocoque construction. Experimental static strain and dynamic shake-testing measurements are presented. Correlation studies of each of these tests with a PC-based finite element analysis (COSMOS/M) are described. The tests included static loadings at the end of the tail cone supported in the cantilever configuration as well as vibrational shake-testing in both the cantilever and free-free configurations.
This report documents mechanical testing capability demonstration activities performed in fiscal year (FY)2025 at Oak Ridge National Laboratory(ORNL)on chromium-coated (Cr-coated) and uncoated advanced zirconium alloy claddings irradiated in the High Flux Isotope Reactor (HFIR) to approximately 4 displacements per atom (dpa), corresponding to ~13GWd/t burnup. Specimens were prepared in axial tension (ATT) and ring tension (RTT) geometries, and passive silicon carbide(SiC)thermometry (TM) was employed to determine irradiation temperatures, which averaged 38–43 °C below the 330 °C design target. Mechanical testing at ambient temperature demonstrated the expected irradiation-induced hardening, with yield strength(YS)and ultimate tensile strength(UTS)values increasing substantially relative to unirradiated counterparts. However, this strengthening was accompanied by a reduction in ductility, as indicated by lower uniform and total elongations(UE and TE). Both coated and uncoated claddings exhibited similar mechanical response, though Cr-coated specimens showed surface cracking perpendicular to the loading direction, attributable to the hardness mismatch between the coating and substrate. Fracture in all cases remained ductile, and no coating spallation was observed following HFIR irradiation. Complementary efforts were directed toward the fabrication of test specimens from commercially irradiated cladding (rod 47I, ~31.1 GWd/t average burnup). Axial sectioning and computer numerical control(CNC)machining successfully produced ATT geometries suitable for benchmarking against HFIR-irradiated specimens. This capability enables direct comparison of cladding behavior between test reactor and commercial reactor environments, thereby supporting the validation of HFIR as a surrogate irradiation platform for accident tolerant fuel (ATF) development. Once HFIR irradiations are completed in FY26,the relevant comparison tests will be completed. Collectively, the FY 2025 PIE campaign has provided mechanical performance data for irradiated advanced claddings The demonstrated capabilities support the framework for mechanical testing and further evaluations in subsequent years. These efforts will represent an important contribution toward the licensing and deployment of Cr-coated zirconium alloy cladding as a near-term ATF solution.