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NASA NTRS2011

2014/2219 Tri-Point Crack Analysis

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. The objective of this study was to evaluate the deformation response at the tips of cracks located in the heat affected zone of friction plug welds and to study the fracture behavior of welds with defects in the form of fatigue cracks. The study used existing 2014-T6 to 2219-T87 self-reacting friction stir weld panels with 2219-T87 friction plug welds. Electro-discharge machined (EDM) notches were machined into the heat affected zone of the plug at the plug-to-base metal interface. Samples were then cycled to generate a fatigue crack emanating from the notch. After the fatigue crack reached a pre-defined length, a speckle pattern was applied and the ARAMIS system (a three dimensional imaging correlation system) was used to measure the deformations at the crack tip under a sequence of loads. Testing was conducted at ambient laboratory conditions. Fracture data from the testing was analyzed to evaluate residual strength capability of the panel as a function of flaw size. ARAMIS strain data was evaluated to examine strain and deformation patterns that develop around the crack tip and at the plug/weld interfaces. Four samples were used in this study, with three samples in a post-weld heat treated condition. Three samples contained large diameter plugs (M5) and one sample contained a small diameter plug (M3). Two samples were 4 inches in width and two samples were 8.5 inches in width. All samples failed through the precrack with residual strengths ranging from 37 ksi to 42 ksi.

Horton, Karla Renee↗

NASA NTRS1990

Idealized tip-to-tail waverider model

The flow field of an idealized cone-derived waverider is axisymmetric. This forebody feature is preserved for the rest of the vehicle, including the inlet, cowl, combustor, and nozzle. There is thus an inviscid, tip-to-tail model in which both the external and internal flows are axisymmetric. The assumption of axial symmetry provides a major simplification for the analysis and allows for a systematic integration of the propulsion unit with the aerodynamics. The code is an initial formulation that provides only the most basic engineering data, such as lift, thrust, drag, and fuel consumption for a point-designed vehicle that may be cruising at a low hypersonic Mach number. The user may specify flight altitude and Mach number, a multiple shock configuration for the inlet, a few basic geometric parameter, H2 or CH4 as fuel, the fuel/air ratio, etc. A new design concept is used for the nozzle that avoids shock waves, minimizes the nozzle length, and may maximize its thrust. A general description of the model is provided with emphasis on the design of the nozzle and fins. Preliminary results are presented that compare the cruise flight range using H2 or CH4 as the fuel.

Emanuel, G.↗

NASA NTRS1985

The computational treatment of supersonic wake flows in INCOREL

Supersonic wake flows are computed in both conical and three-dimensional full potential flows by modeling the wake as a planar cut with a potential discontinuity. Continuity of pressure is satisfied exactly on the wake cut by computing the necessary potential jump at each wake cut grid point. In the conical wake problem, the jump in potential vanishes in the crossflow symmetry plane. Generally, good correlation is achieved for fully three-dimensional wake flows with the planar wake approximation. Matching pressures in the isolated wake flow leads to small variations in the spanwise jump in potential. On the other hand, a small variation in the jump in potential near the wing tip flow can lead to a significant loading in the wake flow if the pressures are not matched.

Siclari, M. J.↗

NASA NTRS1986

Opening and closing of cracks at high cyclic strains

The closure behavior of cracks of different length and at different cyclic strain levels (ranging from predominantly elastic to grossly plastic strains) was studied to observe the effect of residual crack-tip plasticity on crack closure. Cracks were initiated either naturally or artificially (from electric discharge machining pits) in uniaxial test specimens of strengthened alloy steel AISI 4340 with a grain size of 0.016 mm. It was found that, at high strains, cracks closed only when the lowest stress level in the cycle was approached. The stress or the strain opening level depended upon the exact point along the crack length where the observations were made. As the plastic deformation increased, the relative crack opening level was found to decrease and approach the value of stress ratio R. The experimental results were compared with those of three analytical models of crack closure and opening, demonstrating the limitations of the currently available elastic-plastic crack growth analysis.

Iyyer, N. S.↗

NASA NTRS2003

A Reduced Model for Prediction of Thermal and Rotational Effects on Turbine Tip Clearance

This paper describes a dynamic model that was developed to predict changes in turbine tip clearance the radial distance between the end of a turbine blade and the abradable tip seal. The clearance is estimated by using a first principles approach to model the thermal and mechanical effects of engine operating conditions on the turbine sub-components. These effects are summed to determine the resulting clearance. The model is demonstrated via a ground idle to maximum power transient and a lapse-rate takeoff transient. Results show the model demonstrates the expected pinch point behavior. The paper concludes by identifying knowledge gaps and suggesting additional research to improve the model.

Kypuros, Javier A.↗

NASA NTRS2010

Coupled Analysis of an Inlet and Fan for a Quiet Supersonic Jet

A computational analysis of a Gulfstream isentropic external compression supersonic inlet coupled to a Rolls-Royce fan has been completed. The inlet was designed for a small, low sonic boom supersonic vehicle with a design cruise condition of M = 1.6 at 45,000 ft. The inlet design included an annular bypass duct that routed flow subsonically around an engine-mounted gearbox and diverted flow with high shock losses away from the fan tip. Two Reynolds-averaged Navier-Stokes codes were used for the analysis: an axisymmetric code called AVCS for the inlet and a three dimensional (3-D) code called SWIFT for the fan. The codes were coupled at a mixing plane boundary using a separate code for data exchange. The codes were used to determine the performance of the inlet/fan system at the design point and to predict the performance and operability of the system over the flight profile. At the design point the core inlet had a recovery of 96 percent, and the fan operated near its peak efficiency and pressure ratio. A large hub radial distortion generated in the inlet was not eliminated by the fan and could pose a challenge for subsequent booster stages. The system operated stably at all points along the flight profile. Reduced stall margin was seen at low altitude and Mach number where flow separated on the interior lips of the cowl and bypass ducts. The coupled analysis gave consistent solutions at all points on the flight profile that would be difficult or impossible to predict by analysis of isolated components.

Chima, Rodrick V.↗

NASA NTRS1972

Some remarks on elastic crack-tip stress fields.

It is shown that if the displacement field and stress intensity factor are known as functions of crack length for any symmetrical load system acting on a linear elastic body in plane strain, then the stress intensity factor for any other symmetrical load system whatsoever on the same body may be directly determined. The result is closely related to Bueckner's (1970) weight function, through which the stress intensity factor is expressed as a sum of work-like products between applied forces and values of the weight function at their points of application. An example of the method is given wherein the solution for a crack in a remotely uniform stress field is used to generate the expression for the stress intensity factor due to an arbitrary traction distribution on the faces of a crack. A corresponding theory is developed in an appendix for three-dimensional crack problems, although this appears to be directly useful chiefly for problems in which there is axial symmetry.

Rice, J. R.↗

NASA NTRS2011

Analysis of Compression Algorithm in Ground Collision Avoidance Systems (Auto-GCAS)

Automatic Ground Collision Avoidance Systems (Auto-GCAS) utilizes Digital Terrain Elevation Data (DTED) stored onboard a plane to determine potential recovery maneuvers. Because of the current limitations of computer hardware on military airplanes such as the F-22 and F-35, the DTED must be compressed through a lossy technique called binary-tree tip-tilt. The purpose of this study is to determine the accuracy of the compressed data with respect to the original DTED. This study is mainly interested in the magnitude of the error between the two as well as the overall distribution of the errors throughout the DTED. By understanding how the errors of the compression technique are affected by various factors (topography, density of sampling points, sub-sampling techniques, etc.), modifications can be made to the compression technique resulting in better accuracy. This, in turn, would minimize unnecessary activation of A-GCAS during flight as well as maximizing its contribution to fighter safety.

Schmalz, Tyler↗

NASA NTRS1993

Preliminary experimental results for a cryogenic brush seal configuration

Preliminary fluid nitrogen flow data are reported for a five-brush, ceramic-coated-rub-runner brush seal system, where the brushes and the rub runner were placed at each end of a centrally pressurized multifunction tester ('back-to-back' set of brushes) and tested at rotor speeds of 0, 10, 18, and 22.5 krpm. After testing, both the brushes and the ceramic-coated rub runner appeared pristine. The coating withstood both the thermomechanical and dynamic loadings with minor wear track scarring. The bristle tips showed some indication of material shearing (smearing) wear. The Ergun porous flow equation was applied to the brush seal data. The Ergun relation, which required heuristic information to characterize the coefficients, fit the gaseous data but was in poor agreement with the fluid results. The brush seal exit conditions were two phase. Two-phase, choked-flow design charts were applied but required one data point at each rotor speed to define the (C(sub f)A x Constant) flow and area coefficients. Reasonable agreement between prediction and data was found, as expected, but such methods are not to be construed as two-phase-flow brush seal analyses.

Carlile, J. A.↗

NASA NTRS1995

Navier-Stokes Aerodynamic Simulation of the V-22 Osprey on the Intel Paragon MPP

The paper will describe the Development of a general three-dimensional multiple grid zone Navier-Stokes flowfield simulation program (ENS3D-MPP) designed for efficient execution on the Intel Paragon Massively Parallel Processor (MPP) supercomputer, and the subsequent application of this method to the prediction of the viscous flowfield about the V-22 Osprey tiltrotor vehicle. The flowfield simulation code solves the thin Layer or full Navier-Stoke's equation - for viscous flow modeling, or the Euler equations for inviscid flow modeling on a structured multi-zone mesh. In the present paper only viscous simulations will be shown. The governing difference equations are solved using a time marching implicit approximate factorization method with either TVD upwind or central differencing used for the convective terms and central differencing used for the viscous diffusion terms. Steady state or Lime accurate solutions can be calculated. The present paper will focus on steady state applications, although time accurate solution analysis is the ultimate goal of this effort. Laminar viscosity is calculated using Sutherland's law and the Baldwin-Lomax two layer algebraic turbulence model is used to compute the eddy viscosity. The Simulation method uses an arbitrary block, curvilinear grid topology. An automatic grid adaption scheme is incorporated which concentrates grid points in high density gradient regions. A variety of user-specified boundary conditions are available. This paper will present the application of the scalable and superscalable versions to the steady state viscous flow analysis of the V-22 Osprey using a multiple zone global mesh. The mesh consists of a series of sheared cartesian grid blocks with polar grids embedded within to better simulate the wing tip mounted nacelle. MPP solutions will be shown in comparison to equivalent Cray C-90 results and also in comparison to experimental data. Discussions on meshing considerations, wall clock execution time, load balancing, and scalability will be provided.

Vadyak, Joseph↗

NASA NTRS2015

Visualization and Quantification of Rotor Tip Vortices in Helicopter Flows

Helicopter aeromechanics encompasses a highly vortical flow field. The vortices generated at each blade tip contain unsteady, complex, three-dimensional structures, which interact with each other, other blades, the fuselage and various components of the helicopter. It is crucial to understand vortex kinematics and their subsequent dynamic evolution. Much research has been devoted to the understanding of helicopter vortex dynamics, including a number of experimental studies.1-6 In May 2010 Particle Image Velocimetry (PIV) measurements of a full-scale UH-60A rotor were acquired in the National Full-Scale Aerodynamics Complex (NFAC) 40- by 80-Foot Wind Tunnel.1 These measurements were taken at a plane just downstream of the advancing blade in the vicinity of the blade tip—the so-called PIV plane. The resulting PIV data were then processed using an ensemble-average approach to create graphical representations of the vortical wake velocity and vorticity fields, which, in turn, have enhanced the understanding of rotorcraft vortical wake flow field physics and have provided a more detailed validation of vortical wake computer simulations.7 A common approach used to analyze flow field features is to compute and plot color contour maps of various scalar quantities such as pressure, velocity magnitude and vorticity magnitude. For example, the color map of the vorticity magnitude is typically used to determine vortical flow structure. With this approach the vortex core may appear larger or smaller, depending on the contour levels that are selected. Thus, the resulting visualization is sensitive to user-specified contour levels. For vortex core radius measurements, it is more accurate to calculate the vortex core radius using the cross-flow velocity profile across the vortex core. The task of extracting the cross-flow velocity profile can be time consuming with existing tools since the user needs to manually select the core center then specify sampling points along the profile axis. The task becomes even more challenging when the associated grid system uses AMR (Adaptive Mesh Refinement) where the profile axis could span multiple grid blocks. There are a number of existing techniques for profiling of vortex core attributes;8-9 however, these techniques are not fully automatic in that the user still needs to select the vortex core center to compute the cross-flow velocity profile. The present study introduces a new color map scheme that is based on the vortex core radius, which is fully automatic and does not require user intervention. Analysis and visualization of blade tip vortices on the PIV plane using the proposed new color map scheme are described in Section II. The new approach is evaluated using two case studies, which are described in Section III. The paper ends with a summary in Section IV.

Quantification↗

NASA NTRS1976

Altitude performance of a low-noise-technology fan in a turbofan engine with and without a sound suppressing nacelle

Test variables were inlet Reynolds number index (0.2 to 0.5), flight Mach number (0.2 to 0.8), and flow distortion (tip radial and combined circumferential - tip radial patterns). Results are limited to fan bypass and overall engine performance. There were no discernible effects of Reynolds number on fan performance. Increasing flight Mach number shifted the fan operating line such that pressure ratio decreased and airflow increased. Inlet flow distortion lowered stall margin. For a Reynolds number index of 0.2 and flight Mach number of 0.54, the sound suppressing nacelle lowered fan efficiency three points and increased specific fuel consumption about 10 percent.

Biesiadny, T. J.↗

NASA NTRS1987

Arcjet component conditions through a multistart test

A low power, dc arcjet thruster was tested for starting reliability using hydrogen-nitrogen mixtures simulating the decomposition products of hydrazine. More than 300 starts were accumulated in phases with extended burn-in periods interlaced. A high degree of flow stabilization was built into the arcjet and the power supply incorporated both rapid current regulation and a high voltage, pulsed starting circuit. A nominal current level of 10 A was maintained throughout the test. Photomicrographs of the cathode tip showed a rapid recession to a steady-state operating geometry. A target of 300 starts was selected, as this represents significantly more than anticipated (150 to 240), in missions of 10 yr or less duration. Weighings showed no apparent mass loss. Some anode erosion was observed, particularly at the entrance to the constrictor. This was attributed to the brief period during startup the arc mode attachment point spends in the high pressure region upstream of the nozzle. Based on the results obtained, startup does not appear to be performance or life limiting for the number of starts typical of operational satellite applications.

Curran, Frank M.↗

NASA NTRS1987

Arcjet component conditions through a multistart test

Curran, Frank M.↗

NASA NTRS1994

An overview of a model rotor icing test in the NASA Lewis Icing Research Tunnel

During two entries in late 1989, a heavily instrumented sub-scale model of a helicopter main rotor was tested in the NASA LeRC Icing Research Tunnel (IRT). The results of this series of tunnel tests were published previously. After studying the results from the 1989 test and comparing them to predictions, it became clear that certain test conditions still needed investigation. Therefore, a re-entry of the Sikorsky Aircraft Powered Force Model (PFM) in the IRT was instituted in order to expand upon the current rotor craft sub-scale model experimental database. The major areas of interest included expansion of the test matrix to include a larger number of points in the FAA AC 29-2 icing envelope, inclusion of a number of high power rotor performance points, close examination of warm temperature operations, operation of the model in constant lift mode, and testing for conditions for icing test points in the full scale helicopter database. The expanded database will allow further and more detailed examination and comparison with analytical models. Participants in the test were NASA LeRC, the U.S. Army Vehicle Propulsion Directorate based at LeRC, and Sikorsky Aircraft. The model rotor was exposed to a range of icing conditions (temperature, liquid water content, median droplet diameter) and was operated over ranges of shaft angle, rotor tip speed, advance ratio, and rotor lift. The data taken included blade strain gage and balance data, as well as still photography, video, ice profile tracings, and ice molds. A discussion of the details of the test is given herein. Also, a brief examination of a subset of the data taken is also given.

Britton, Randall K.↗

NASA NTRS1985

Comparative evaluations of the geodetic accuracy and cartographic potential of Landsat-4 and Landsat-5 Thematic Mapper image data

A Landsat Image Data Quality Analysis (LIDQA) Program is conducted by NASA. One part of this program forms studies which are being performed with the objective to evaluate the geometric fidelity of Landsat-4 and Landsat-5 Thematic Mapper (TM) data in computer tape (CCT-pt) formats. It is pointed out that the Landsat-4 and Landsat-5 systems provide image data of significantly better geometric fidelity than were obtained from the earlier Landsat missions. Attention is given to the factors which influence the geometric fidelity of the Landsat TM data, the study areas and data sets, the rectification procedures, the rectification of Landsat-4 TM data and comparisons of the Scrounge and the TM Image Processing System (TIPS), the rectification of system and scene corrected Landsat-5 data processed on TIPS, and the cartographic potential of TM data.

Welch, R.↗

NASA NTRS1986

Vortex flow hysteresis

An experimental study was conducted to quantify the hysteresis associated with various vortex flow transition points and to determine the effect of planform geometry. The transition points observed consisted of the appearance (or disappearance) of trailing edge vortex burst and the transition to (or from) flat plate or totally separated flows. Flow visualization with smoke injected into the vortices was used to identify the transitions on a series of semi-span models tested in a low speed tunnel. The planforms tested included simple deltas (55 deg to 80 deg sweep), cranked wings with varying tip panel sweep and dihedral, and a straked wing. High speed movies at 1000 frames per second were made of the vortex flow visualization in order to better understand the dynamics of vortex flow, burst and transition.

Cunningham, A. M., Jr.↗

NASA NTRS1999

Testing and Analysis of Composite Skin/Stringer Debonding Under Multi-Axial Loading

Damage mechanisms in composite bonded skin/stringer constructions under uniaxial and biaxial (in-plane/out- of-plane) loading conditions were examined. Specimens consisted of a tapered composite flange bonded onto a composite skin. Tests were performed under monotonic loading conditions in tension, three-point bending, and combined tension/bending . For combined tension/bending testing, a unique servohydraulic load frame was used that was capable of applying both in-plane tension and out-of-plane bending loads simultaneously. Specimen edges were examined on the microscope to document the damage occurrence and to identify typical damage patterns. The observations showed that, for all three load cases, failure initiated in the flange, near the flange tip, causing the flange to almost fully debond from the skin. A two-dimensional plane-strain finite element model was developed to analyze the different test cases using a geometrically nonlinear solution. For all three loading conditions, principal stresses exceeded the transverse strength of the material in the flange area. Additionally, delaminations of various lengths were simulated in two locations where delaminations were observed. The analyses showed that unstable delamination propagation is likely to occur in one location at the loads corresponding to matrix ply crack initiation for all three load cases.

Krueger, Ronald↗