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At least 523 records · Page 29

Effect of Crystal Orientation on Analysis of Single-Crystal, Nickel-Based Turbine Blade Superalloys

High-cycle fatigue-induced failures in turbine and turbopump blades is a pervasive problem. Single-crystal nickel turbine blades are used because of their superior creep, stress rupture, melt resistance, and thermomechanical fatigue capabilities. Single-crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant and complicating factor. A fatigue failure criterion based on the maximum shear stress amplitude on the 24 octahedral and 6 cube slip systems is presented for single-crystal nickel superalloys (FCC crystal). This criterion greatly reduces the scatter in uniaxial fatigue data for PWA 1493 at 1,200 F in air. Additionally, single-crystal turbine blades used in the Space Shuttle main engine high pressure fuel turbopump/alternate turbopump are modeled using a three-dimensional finite element (FE) model. This model accounts for material orthotrophy and crystal orientation. Fatigue life of the blade tip is computed using FE stress results and the failure criterion that was developed. Stress analysis results in the blade attachment region are also presented. Results demonstrate that control of crystallographic orientation has the potential to significantly increase a component's resistance to fatigue crack growth without adding additional weight or cost.

Swanson, G. R.↗

The 3-D inelastic analysis methods for hot section components: Brief description

Advanced 3-D inelastic structural/stress analysis methods and solution strategies for more accurate yet more cost-effective analysis of components subjected to severe thermal gradients and loads in the presence of mechanical loads, with steep stress and strain gradients are being developed. Anisotropy, time and temperature dependent plasticity and creep effects are also addressed. The approach is to develop four different theories, one linear and three higher order theories (polynomial function, special function, general function). The theories are progressively more complex from linear to general function in order to provide streamlined analysis capability with increasing accuracy for each hot section component and for different parts of the same component according to the severity of the local stress, strain and temperature gradients associated with hot spots, cooling holes and surface coating cracks. To further enhance the computational effectiveness, the higher order theories will have embedded singularities (cooling passages, for example) in the generic modeling region. Each of the four theories consists of three formulation models derivable from independent theoretical formulations. These formulation models are based on: (1) mechanics of materials; (2) special finite elements; and (3) an advanced formulation to be recommended by the contractor.

Chamis, C. C.↗

Advanced Environmental Barrier Coating Development for SiC/SiC Ceramic Matrix Composites: NASA's Perspectives

This presentation reviews NASA environmental barrier coating (EBC) system development programs and the coating materials evolutions for protecting the SiC/SiC Ceramic Matrix Composites in order to meet the next generation engine performance requirements. The presentation focuses on several generations of NASA EBC systems, EBC-CMC component system technologies for SiC/SiC ceramic matrix composite combustors and turbine airfoils, highlighting the temperature capability and durability improvements in simulated engine high heat flux, high pressure, high velocity, and with mechanical creep and fatigue loading conditions. The current EBC development emphasis is placed on advanced NASA 2700F candidate environmental barrier coating systems for SiC/SiC CMCs, their performance benefits and design limitations in long-term operation and combustion environments. Major technical barriers in developing environmental barrier coating systems, the coating integrations with next generation CMCs having the improved environmental stability, erosion-impact resistance, and long-term fatigue-environment system durability performance are described. The research and development opportunities for advanced turbine airfoil environmental barrier coating systems by utilizing improved compositions, state-of-the-art processing methods, and simulated environment testing and durability modeling are discussed.

Ceramic Matrix Composites↗

Effect of Crystal Orientation on Fatigue Failure of Single Crystal Nickel Base Turbine Blade Superalloys

High Cycle Fatigue (HCF) induced failures in aircraft gas-turbine engines is a pervasive problem affecting a wide range of components and materials. HCF is currently the primary cause of component failures in gas turbine aircraft engines. Turbine blades in high performance aircraft and rocket engines are increasingly being made of single crystal nickel superalloys. Single-crystal Nickel-base superalloys were developed to provide superior creep, stress rupture, melt resistance and thermomechanical fatigue capabilities over polycrystalline alloys previously used in the production of turbine blades and vanes. Currently the most widely used single crystal turbine blade superalloys are PWA 1480/1493 and PWA 1484. These alloys play an important role in commercial, military and space propulsion systems. PWA1493, identical to PWA1480, but with tighter chemical constituent control, is used in the NASA SSME (Space Shuttle Main Engine) alternate turbopump, a liquid hydrogen fueled rocket engine. Objectives for this paper are motivated by the need for developing failure criteria and fatigue life evaluation procedures for high temperature single crystal components, using available fatigue data and finite element modeling of turbine blades. Using the FE (finite element) stress analysis results and the fatigue life relations developed, the effect of variation of primary and secondary crystal orientations on life is determined, at critical blade locations. The most advantageous crystal orientation for a given blade design is determined. Results presented demonstrates that control of secondary and primary crystallographic orientation has the potential to optimize blade design by increasing its resistance to fatigue crack growth without adding additional weight or cost.

Arakere, Nagaraj K.↗

Longitudinal aerodynamic characteristics of a subsonic, energy-efficient transport configuration in the National Transonic Facility

The Reynolds number, aeroelasticity, boundary layer transition, and nonadiabatic wall temperature effects, and data repeatability was determined in the National Transonic Facility (NTF) for a subsonic, energy efficient transport model. The model was tested over a Mach number range of 0.50 to 0.86 and a Reynolds number range of 1.9 million to approximately 23.0 million (based on mean geometric chord). The majority of the data was taken using cryogenic nitrogen (data at 1.9 million Reynolds number was taken in air). Force and moment, wing pressure, and wing thermocouple data are presented. The data indicate that increasing Reynolds number resulted in greater effective camber of the supercritical wing and horizontal tail, resulting in greater lift and pitching moment coefficients at nearly all angles of attack for M = 0.82. As Reynolds number was increased, untrimmed L/D increased, the angle of attack for maximum L/D decreased, drag creep was reduced significantly, and drag divergence Mach number increased slightly. Data repeatability for both modes of operation of the NTF (air and cryogenic nitrogen) was generally very good, and nonadiabatic wall effects were estimated to be small. Transition-free and transition-fixed configurations had significantly different force and moment data at M = 0.82 for low Reynolds number, and very small differences were noted at high Reynolds numbers.

Jacobs, Peter F.↗

The Face that Launched a Thousand Slips

Helene, (approximately 17.6 kilometers mean radius) is an L4 Trojan co-orbital of Saturn's moon Dione. Its hemisphere features an unusual morphology consisting of broad depressions and a generally smooth surface patterned with streaks and grooves. The streaks appear to be oriented down-gradient, as are the grooves. This pattern suggests intensive mass-wasting as a dominant process on the leading hemisphere. Kilometer-scale impact craters are very sparse on the leading hemisphere other than the degraded kilometer-scale basins defining the overall satellite shape, and many small craters have a diffuse appearance suggesting ongoing mass wasting. Thus mass wasting must dominate surface-modifying processes at present. In fact, the mass wasting appears to have been sufficient in magnitude to narrow the divides between adjacent basins to narrow septa, similar, but in lower relief, to the honeycomb pattern of Hyperion. The prominent groves occur primarily near topographic divides and appear have cut into a broad, slightly lower albedo surface largely conforming to the present topography but elevated a few meters above the smooth surfaces undergoing mass wasting flow. Low ridges and albedo markings on the surface suggest surface flow of materials traveling up to several kilometers. Diffusive mass wasting produces smooth surfaces - such a pattern characterizes most of the low-lying surfaces. The grooves, however, imply that the transport process is advective at those locations where they occur, that is, erosion tends to concentrate along linear pathways separated by divides. In fact, in many places grooves have a fairly regular spacing of 125-160 meters, defining a characteristic erosional scale. Several questions are prompted by the unusual morphology of Helene: 1) What is the nature of the surface materials? 2) Are the transport processes gradual or catastrophic motion from one or a few events? 3) What mechanisms drive mass wasting and groove development? 4) Have the formative processes been active in the recent past? 5) Finally, is the surface accreting or eroding? The smooth character of the leading edge hemisphere of Helene and the dominance of mass wasting suggest that the surface is composed of fine-grained debris, probably dominated by dust-size to small gravel particles. The Lagrangian points of saturnian satellites are locations where planetesimals might have accreted to form co-orbital satellites such as and they may capture ejecta from their master moon. Published models suggest that Helene is a site of net accretion, but we find no extant explanation for the dominance of fine grain sizes for the surface (and probable subsurface) composition of Helene and the other Lagrangian satellites. Observation of the mass wasting tracks on Helene suggests the presence of well-defined streams of debris with low bordering levees that may be depositional features or remnants of the dissected higher surface. Some flows in grazing illumination appear to have a convex cross-section. This mass-flow morphology might be consistent with the occurrence of large-scale flow events, but which might have occurred through rapid emplacement or slow glacier-like creep. On the other hand, small craters appear to have been "softened" by creep-like processes, indicating ongoing mass wasting.

honeycomb pattern of Hyperion↗

Mantle viscosity - A comparison of models from postglacial rebound and from the geoid, plate driving forces, and advected heat flux

Models of the radial variation of effective viscosity inferred from the earth's response to surface loads associated with Pleistocene deglaciation are compared to structures inferred from models of geodynamic phenomena associated with convection: the geoid, plate-driving forces, and advected heat flux. While observations of the earth's response to surface loads do not have sufficient resolution to justify more than two viscous layers, adequately matching the observed long-wavelength geoid anomalies associated with density contrasts in the lower mantle (inferred from seismic tomography) and in the upper mantle (inferred from a model of subducted slabs) requires more structure. It is possible to explain the geoid, observed plate velocities, the advected heat flux in the lower mantle, and relative sea-level variations in oceanic regions, all with a mantle with a high-viscosity/elastic lid, an asthenospheric channel of 2 x 10 exp 19 Pa s from 100 to 400-km depth, a 6 x 10 exp 20 Pa s transition zone, and a lower mantle of 6 x 10 exp 21 Pa s. The uplift history of Australia, Fennoscandia, and Laurentia can be explained with an asthenospheric viscosity less than a factor of 10 higher. Lateral variations in lower mantle viscosity are not required. Transient creep appears to be unimportant for the recent response-to-surface loads from Pleistocene deglaciation.

Hager, Bradford H.↗

NASA GRC Fatigue Crack Initiation Life Prediction Models

Metal fatigue has plagued structural components for centuries, and it remains a critical durability issue in today's aerospace hardware. This is true despite vastly improved and advanced materials, increased mechanistic understanding, and development of accurate structural analysis and advanced fatigue life prediction tools. Each advance is quickly taken advantage of to produce safer, more reliable, more cost effective, and better performing products. In other words, as the envelope is expanded, components are then designed to operate just as close to the newly expanded envelope as they were to the initial one. The problem is perennial. The economic importance of addressing structural durability issues early in the design process is emphasized. Tradeoffs with performance, cost, and legislated restrictions are pointed out. Several aspects of structural durability of advanced systems, advanced materials and advanced fatigue life prediction methods are presented. Specific items include the basic elements of durability analysis, conventional designs, barriers to be overcome for advanced systems, high-temperature life prediction for both creep-fatigue and thermomechanical fatigue, mean stress effects, multiaxial stress-strain states, and cumulative fatigue damage accumulation assessment.

Arya, Vinod K.↗

Inelastic deformation of metal matrix composites

A theoretical model capable of predicting the thermomechanical response of continuously reinforced metal matrix composite laminates subjected to multiaxial loading was developed. A micromechanical model is used in conjunction with nonlinear lamination theory to determine inelastic laminae response. Matrix viscoplasticity, residual stresses, and damage to the fiber/matrix interfacial zone are explicitly included in the model. The representative cell of the micromechanical model is considered to be in a state of generalized plane strain, enabling a quasi two-dimensional analysis to be performed. Constant strain finite elements are formulated with elastic-viscoplastic constitutive equations. Interfacial debonding is incorporated into the model through interface elements based on the interfacial debonding theory originally presented by Needleman, and modified by Tvergaard. Nonlinear interfacial constitutive equations relate interfacial tractions to displacement discontinuities at the interface. Theoretical predictions are compared with the results of an experimental program conducted on silicon carbide/titanium (SiC/Ti) unidirectional, (O4), and angle-ply, (+34)(sub s), tubular specimens. Multiaxial loading included increments of axial tension, compression, torque, and internal pressure. Loadings were chosen in an effort to distinguish inelastic deformation due to damage from matrix plasticity and separate time-dependent effects from time-independent effects. Results show that fiber/matrix debonding is nonuniform throughout the composite and is a major factor in the effective response. Also, significant creep behavior occurs at relatively low applied stress levels at room temperature.

Lissenden, C. J.↗

The non-hydrostatic figures of the terrestrial planets

Solid state creep being exponentially dependent on temperature must dominate the mechanical behavior of the mantles of terrestrial planets beneath their lithospheres. General arguments suggest that the lithospheres of the Moon and Mars are about 200 km thick; the Earth, Venus and Mercury much less. Short wavelength gravity anomalies are explained by the finite strength of the lithosphere: the lunar mascons being an example. The good correlation of the Venus and Mars gravity anomalies with topography up to spherical harmonics of degrees 10-15 is in striking contrast to the lack of correlation between the long wavelength components of the geoid and the continent-ocean distribution or even the plates. Attempts have been made to explain the former correlations by isostatic models but the depths of compensation seem implausible. Low degree harmonics of the gravity fields of the terrestrial planets as is certainly the case in the Earth must arise from the density variations driving solid state convection. In the case of Venus the less dense differentiated materials of the highlands seems to be positioned over the singular points of the convection pattern. Thus the correlated gravity field does not arise from the highlands but from the density difference in the convecting interior. In the Earth lack of correlation seems to arise from the fact that the plates have moved relative to the convection pattern the last 100 M yr.

Runcorn, S. K.↗

Creep fatigue life prediction for engine hot section materials (isotropic)

The Hot Section Technology (HOST) program, creep fatigue life prediction for engine hot section materials (isotropic), is reviewed. The program is aimed at improving the high temperature crack initiation life prediction technology for gas turbine hot section components. Significant results include: (1) cast B1900 and wrought IN 718 selected as the base and alternative materials respectively; (2) fatigue test specimens indicated that measurable surface cracks appear early in the specimen lives, i.e., 15% of total life at 871 C and 50% of life at 538 c; (3) observed crack initiation sites are all surface initiated and are associated with either grain boundary carbides or local porosity, transgrannular cracking is observed at the initiation site for all conditions tested; and (4) an initial evaluation of two life prediction models, representative of macroscopic (Coffin-Mason) and more microscopic (damage rate) approaches, was conducted using limited data generated at 871 C and 538 C. It is found that the microscopic approach provides a more accurate regression of the data used to determine crack initiation model constants, but overpredicts the effect of strain rate on crack initiation life for the conditions tested.

Moreno, V.↗

Life prediction modeling based on strainrange partitioning

Strainrange partitioning (SRP) is an integrated low-cycle-fatigue life predicting system. It was created specifically for calculating cyclic crack initiation life under severe high-temperature fatigue conditions. The key feature of the SRP system is its recognition of the interacting mechanisms of cyclic inelastic deformation that govern cyclic life at high temperatures. The SRP system bridges the gap between the mechanistic level of understanding that breeds new and better materials and the phenomenological level wherein workable engineering life prediction methods are in great demand. The system was recently expanded to address engineering fatigue problems in the low-strain, long-life, nominally elastic regime. This breakthrough, along with other advances in material behavior and testing technology, has permitted the system to also encompass low-strain thermomechanical loading conditions. Other important refinements of the originally proposed method include procedures for dealing with life-reducing effects of multiaxial loading, ratcheting, mean stresses, nonrepetitive (cumulative loading) loading, and environmental and long-time exposure. Procedure were also developed for partitioning creep and plastic strain and for estimating strainrange versus life relations from tensile and creep rupture properties. Each of the important engineering features of the SRP system are discussed and examples shown of how they help toward predicting high-temperature fatigue life under practical, although complex, loading conditions.

Halford, Gary R.↗

An Investigation of SiC/SiC Woven Composite Under Monotonic and Cyclic Loading

The desirable properties in ceramic matrix composites (CMCs), such as high temperature strength, corrosion resistance, high toughness, low density, or good creep resistance have led to increased use of CMCs in high-speed engine structural components and structures that operate in extreme temperature and hostile aero-thermo-chemical environments. Ceramic matrix composites have been chosen for turbine material in the design of 21 st-century civil propulsion systems to achieve high fuel economy, improved reliability, extended life, and reduced cost. Most commercial CMCs are manufactured using a chemical vapor infiltration (CVI) process. However, a lower cost fabrication known as melt-infiltration process is also providing CMCs marked for use in hot sections of high-speed civil transports. The scope of this paper is to report on the material and mechanical characterization of the CMCs subjected to this process and to predict the behavior through an analytical model. An investigation of the SiC/SiC 8-harness woven composite is ongoing and its tensile strength and fatigue behavior is being characterized for room and elevated temperatures. The investigation is being conducted at below and above the matrix cracking stress once these parameters are identified. Fractography and light microscopy results are being studied to characterize the failure modes resulting from pure uniaxial loading. A numerical model is also being developed to predict the laminate properties by using the constituent material properties and tow undulation.

Lang, J.↗

Synergistic Effects of Physical Aging and Damage on Long-Term Behavior of Polymer Matrix Composites

The research consisted of two major parts, first modeling and simulation of the combined effects of aging and damage on polymer composites and secondly an experimental phase examining composite response at elevated temperatures, again activating both aging and damage. For the simulation, a damage model for polymeric composite laminates operating at elevated temperatures was developed. Viscoelastic behavior of the material is accounted for via the correspondence principle and a variational approach is adopted to compute the temporal stresses within the laminate. Also, the effect of physical aging on ply level stress and on overall laminate behavior is included. An important feature of the model is that damage evolution predictions for viscoelastic laminates can be made. This allows us to track the mechanical response of the laminate up to large load levels though within the confines of linear viscoelastic constitutive behavior. An experimental investigation of microcracking and physical aging effects in polymer matrix composites was also pursued. The goal of the study was to assess the impact of aging on damage accumulation, in ten-ns of microcracking, and the impact of damage on aging and viscoelastic behavior. The testing was performed both at room and elevated temperatures on [+/- 45/903](sub s) and [02/903](sub s) laminates, both containing a set of 90 deg plies centrally located to facilitate investigation of microcracking. Edge replication and X-ray-radiography were utilized to quantify damage. Sequenced creep tests were performed to characterize viscoelastic and aging parameters. Results indicate that while the aging times studied have limited ]Influence on damage evolution, elevated temperature and viscoelastic effects have a profound effect on the damage mode seen. Some results are counterintuitive, including the lower strain to failure for elevated temperature tests and the catastrophic failure mode observed for the [+/- 45/9O3](sub s), specimens. The fracture toughness for transverse cracks increases with increasing temperature for both systems: transverse cracking was completely absent prior to failure in [+/- 45/903](sub s), and was suppressed for [02/903](sub s). No significant effect of damage on aging or viscoelastic parameters was observed.

Brinson, L. Cate↗

Factors Influencing Dwell Fatigue Cracking in Notches of Powder Metallurgy Superalloys

The influences of heat treatment and cyclic dwells on the notch fatigue resistance of powder metallurgy disk superalloys were investigated for low solvus high refractory (LSHR) and ME3 disk alloys. Disks were processed to produce material conditions with varied microstructures and associated mechanical properties. Notched specimens were first subjected to baseline dwell fatigue cycles having a dwell at maximum load, as well as tensile, stress relaxation, creep rupture, and dwell fatigue crack growth tests at 704 C. Several material heat treatments displayed a bimodal distribution of fatigue life with the lives varying by two orders-of-magnitude, while others had more consistent fatigue lives. This response was compared to other mechanical properties, in search of correlations. The wide scatter in baseline dwell fatigue life was observed only for material conditions resistant to stress relaxation. For selected materials and conditions, additional tests were then performed with the dwells shifted in part or in total to minimum tensile load. The tests performed with dwells at minimum load exhibited lower fatigue lives than max dwell tests, and also exhibited early crack initiation and a substantial increase in the number of initiation sites. These results could be explained in part by modeling evolution of peak stresses in the notch with continued dwell fatigue cycling. Fatigue-environment interactions were determined to limit life for the fatigue cycles with dwells.

Gabb, T. P.↗

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic stresses. It is found that in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗

Ab-Initio Study of Stacking Fault Segregation Behavior in Ni-based Superalloys at High Temperatures

Ni-based superalloys demonstrate extraordinary creep properties compared to traditional metallic systems due to the formation of L12 (γ’) precipitates. Despite experimental evidence of alloying element segregation to the stacking faults, prior ab-initio efforts indicated repulsion of Nb from superlattice intrinsic stacking faults (SISFs) . Due to the importance of this element in key strengthening mechanisms, we developed a new technique to account for multi-component segregation behavior at temperature combining ab-initio molecular dynamics (AIMD) and Monte-Carlo (MC) simulations. Using this technique, we replicated experimentally observed segregation behavior of Nb, Co, and Ti to the SISF in L12 (Figure 1). Furthermore, we investigated the co-segregation behaviors of individual pairs of alloying elements to determine the interaction effects which lead to this segregation behavior in the full alloy system. By simulating the reduced-chemistry models using our approach, we reconciled previous ab-initio calculations demonstrating repulsion of Nb from the SISF and the experimentally observed segregation behavior.

Molecular Dynamics↗

Geometric Acoustics for Aircraft Noise Scattering

This paper discusses aircraft noise scattering by geometric acoustics, which consists of the basic features of sound propagation and reflection in rays or ray tubes, diffraction by smooth geometry in terms of surface creeping waves, and diffraction by abrupt geometry features such as the wing trailing edges. Based on the classic theories of these features, prediction methodologies can be constructed for aircraft noise scattering. The methodologies, however, require important modifications and extensions to account for unique features in aircraft noise applications, for both current conventional aircraft and future unconventional designs. These modifications and extensions include the derivation of a general reflection coefficient that contains the effects of surface geometry curvature, surface impedance, and mean flow. Corrections to the basic formulation of diffraction, both smooth geometry and sharp edges, are formulated to account for the finite dimensions of practical applications. For smooth geometry diffraction, a second order correction is used to continuously transition from insolified to shadow zones and an approach is presented to compute the properties of the geodesic path of surface wave propagation. A model is developed to make use of the ray propagation formulation for incoherent and partially coherent propagation and scattering, which is an important phenomenon in aircraft noise. Mean flow effect is also included in the methodology for low Mach number flows. Examples of calculations based on these theoretical developments are presented to illustrate the unique features in aircraft noise applications.

Yueping Guo↗