Advanced Approaches to Fatigue Evaluation
Conference on fatigue test evaluation for aircraft structures
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Practical aspects of designing for and evaluating structural integrity
The application of procedures for designing and evaluating structural integrity of various construction techniques is discussed. The fatigue performance improvement of the following conditions is described: (1) conical fasteners, (2) hole preparation, (3) interference fit, and (4) interference protection. The application of fatigue tests to determine fail-safe conditions is analyzed.
Peyrony, M.↗
Reliability improvement of 1 mil aluminum wire bonds for semiconductors, technical performance summary
The reliability of semiconductor devices as influenced by the reliability of wire bonds used in the assembly of the devices is investigated. The specific type of failure dealt with involves fracture of wire bonds as a result of repeated flexure of the wire at the heel of the bond when the devices are operated in an on-off mode. The mechanism of failure is one of induced fracture of the wire. To improve the reliability of a chosen transistor, one-mil diameter wires of aluminum with various alloy additions were studied using an accelerated fatigue testing machine. In addition, the electroprobe was used to study the metallurgy of the wires as to microstructure and kinetics of the growth of insoluble phases. Thermocompression and ultrasonic bonding techniques were also investigated.
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Study to determine and analyze the strength of high modulus glass in epoxy-matrix composites
Glass composition research was conducted to produce a high modulus, high strength beryllium-free glass fiber. This program was built on the previous research for developing high modulus, high strength glass fibers which had a 5 weight percent beryllia content. The fibers resulting from the composition program were then used to produce fiber reinforced-epoxy resin composites which were compared with composites reinforced by commercial high modulus glass fibers, Thornel S graphite fiber, and hybrids where the external quarters were reinforced with Thornel S graphite fiber and the interior half with glass fiber as well as the reverse hybrid. The composites were given tensile strength, compressive strength, short-beam shear strength, creep and fatigue tests. Comments are included on the significance of the test data.
Bacon, J. F.↗
Silicon nitride used as a rolling-element bearing material
Rolling-element fatigue tests were conducted with hot-pressed silicon nitride to determine its ability to withstand concentrated contacts in rolling-element bearings. If hot-pressed silicon nitride is used for both balls and races, attention must be paid to fitting both shaft and bearing housing.
Parker, R. J.↗
Coatings for directional eutectics
Eleven coating systems based on MCrAlY overlay and diffusion aluminide prototypes were evaluated to determine their capability for protecting the gamma/gamma prime-delta directionally solidified eutectic alloy (Ni-20Cb-6Cr-2.5Al) in gas turbine engine applications. Furnace oxidation and hot corrosion, Mach 0.37 burner-rig, tensile ductility, stress-rupture and thermomechanical fatigue tests were used to evaluate the coated gamma/gamma prime-delta alloy. The diffusion aluminide coatings provided adequate oxidation resistance at 1144 K (1600 F) but offered very limited protection in 114 K (1600 F) hot corrosion and 1366 K (2000 F) oxidation tests. A platinum modified NiCrAlY overlay coating exhibited excellent performance in oxidation testing and had no adverse effects upon the eutectic alloy.
Felten, E. J.↗
Bending stresses in spherically hollow ball bearing and fatigue experiments
Spherically hollow balls of 21.7, 50.0, and 56.5 percent mass reduction were operated in ball bearings and in a five-ball fatigue tester with differing outcomes. Available theoretical and experimental treatments of stresses in spherically hollow balls are reviewed and compared. Bending stresses are estimated for these spherically hollow balls to better understand the differences in ball bearing and fatigue test experience.
Nypan, L. J.↗
Application of strainrange partitioning to the prediction of creep-fatigue lives of AISI types 304 and 316 stainless steel
As a demonstration of the predictive capabilities of the method of Strainrange Partitioning, published high-temperature, low cycle, creep-fatigue test results on AISI Types 304 and 316 stainless steel were analyzed and calculated, cyclic lives compared with observed lives. Predicted lives agreed with observed lives within factors of two for 76 percent, factors of three for 93 percent, and factors of four for 98 percent of the laboratory tests analyzed. Agreement between observed and predicted lives is judged satisfactory considering that the data are associated with a number of variables (two alloys, several heats and heat treatments, a range of temperatures, different testing techniques, etc.) that are not directly accounted for in the calculations.
Saltsman, J. F.↗
YF-12 Lockalloy ventral fin program, volume 1
Results are presented of the YF-12 Lockalloy Ventral Fin Program which was carried out by Lockheed Aircraft Corporation - Advanced Development Projects for the joint NASA/USAF YF-12 Project. The primary purpose of the program was to redesign and fabricate the ventral fin of the YF-12 research airplane (to reduce flutter) using Lockalloy, and alloy of beryllium and aluminum, as a major structural material. A secondary purpose, was to make a material characterization study (thermodynamic properties, corrosion; fatigue tests, mechanical properties) of Lockalloy to validate the design of the ventral fin and expand the existing data base on this material. All significant information pertinent to the design and fabrication of the ventral fin is covered. Emphasis throughout is given to Lockalloy fabrication and machining techniques and attendant personnel safety precautions. Costs are also examined. Photographs of tested alloy specimens are shown along with the test equipment used.
Duba, R. J.↗
Evaluation of hybrid composite materials in cylindrical specimen geometries
Static and fatigue properties of three composite materials and hybrids were examined. The materials investigated were graphite/epoxy, S-glass/epoxy, PRD-49 (Kevlar 49)/epoxy, and hybrids in angle-ply configurations. A new type of edgeless cylindrical specimen was developed. It is a flattened tube with two flat sides connected by curved sections and it is handled much like the standard flat coupon. Special specimen fabrication, tabbing, and tab region reinforcing techniques were developed. Axial modulus, Poisson's ratio, strength, and ultimate strain were obtained under static loading from flattened tube specimens of nine laminate configurations. In the case of graphite/epoxy the tubular specimens appeared to yield somewhat higher strength and ultimate strain values than flat specimens. Tensile fatigue tests were conducted with all nine types of specimens and S-N curves obtained. Specimens surviving 10 million cycles of tensile loading were subsequently tested statically to failure to determine residual properties.
Liber, T.↗
Bending stresses in spherically hollow ball bearing and fatigue experiments
Spherically hollow balls of 21.7, 50.0 and 56.5 per cent mass reduction have been operated in ball bearings and in a 5-ball fatigue tester with differing outcomes. Available theoretical and experimental treatments of stresses in spherically hollow balls are reviewed and compared. Bending stresses are estimated for these spherically hollow balls to better understand the differences in ball bearing and fatigue test experience.
Nypan, L. J.↗
Bearingless helicopter main rotor development. Volume 2: Combined load fatigue evaluation of weathered graphite/epoxy composite
Small scale combined load fatigue tests were conducted on six artificially and six naturally weathered test specimens. The test specimen material was unidirectionally oriented A-S graphite - woven glass scrim epoxy resin laminate.
Rackiewicz, J. J.↗
Application of Strainrange Partitioning to the prediction of creep-fatigue lives of AISI Types 304 and 316 stainless steel
As a demonstration of the predictive capabilities of the method of Strainrange Partitioning, published high-temperature, low cycle, creep-fatigue test results on AISI Types 304 and 316 stainless steel were analyzed and calculated cyclic lives compared with observed lives. Predicted lives agreed with observed lives within factors of two for 76 percent, factors of three for 93 percent, and factors of four for 98 percent of the laboratory tests analyzed. Agreement between observed and predicted lives is judged satisfactory considering that the data are associated with a number of variables (two alloys, several heats and heat treatments, a range of temperatures, different testing techniques, etc.) that are not directly accounted for in the calculations.
Saltsman, J. F.↗
Design of rotors for improved structural life
Major rotor design criteria are discussed with particular emphasis on those aspects of rotor design that ensure long life component integrity. Dynamic considerations, that necessitate tuning of bladed disk and seal assemblies to avoid excessive vibratory stress at both design and off-design conditions are reviewed as well as low cycle fatigue considerations, which have resulted in detailed analysis procedures to establish part temperature and stress variation throughout an operating cycle and extensive specimen and component fatigue testing to establish safe cyclic operating limits. The frequency, size, and behavior of intrinsic material defects were investigated. Manufacturing process improvements, including the application of increasingly sophisticated inspection techniques and quality control procedures are reviewed in light of their impact on component durability.
Hill, J. T.↗
The use of an ion-beam source to alter the surface morphology of biological implant materials
An electron bombardment, ion thruster was used as a neutralized-ion beam sputtering source to texture the surfaces of biological implant materials. Scanning electron microscopy was used to determine surface morphology changes of all materials after ion-texturing. Electron spectroscopy for chemical analysis was used to determine the effects of ion texturing on the surface chemical composition of some polymers. Liquid contact angle data were obtained for ion textured and untextured polymer samples. Results of tensile and fatigue tests of ion-textured metal alloys are presented. Preliminary data of tissue response to ion textured surfaces of some metals, polytetrafluoroethylene, alumina, and segmented polyurethane were obtained.
Weigand, A. J.↗
Filtration effects on ball bearing life and condition in a contaminated lubricant
Ball bearings were fatigue tested with a noncontaminated lubricant and with a contaminated lubricant under four levels of filtration. The test filters had absolute particle removal ratings of 3, 30, 49, and 105 microns. Aircraft turbine engine contaminants were injected into the filter's supply line at a constant rate of 125 milligrams per bearing hour. Bearing life and running track condition generally improved with finer filtration. The experimental lives of 3 and 30 micron filter bearings were statistically equivalent, approaching those obtained with the noncontaminated lubricant bearings. Compared to these bearings, the lives of the 49 micron bearings were statistically lower. The 105 micron bearings experienced gross wear. The degree of surface distress, weight loss, and probable failure mode were dependent on filtration level, with finer filtration being clearly beneficial.
Loewenthal, S. H.↗
Effect of filtration on rolling-element-bearing life in contaminated lubricant environment
Fatigue tests were conducted on groups of 65 millimeter-bore ball bearings under four levels of filtration with and without a contaminated MIL-L-23699 lubricant. The baseline series used noncontaminated oil with 49 micron absolute filtration. In the remaining tests contaminants of the composition found in aircraft engine filters were injected into the filter's supply line at a constant rate of 125 milligrams per bearing-hour. The test filters had absolute particle removal ratings of 3, 30, 49, and 105 microns (0.45, 10, 30, and 70 microns nominal), respectively. Bearings were tested at 15,000 rpm under 4580 newtons radial load. Bearing life and running tract condition generally improved with finer filtration. The 3 and 30 micron filter bearings in a contaminated lubricant had statistically equivalent lives, approaching those from the baseline tests. The experimental lives of 49 micron bearings were approximately half the baseline bearing's lives. Bearings tested with the 105 micron filter experienced wear failures. The degree of surface distress, weight loss, and probable failure mode were found to be dependent on filtration level, with finer filtration being clearly beneficial.
Loewenthal, S. H.↗
The use of an ion-beam source to alter the surface morphology of biological implant materials
An electron-bombardment ion-thruster was used as a neutralized-ion-beam sputtering source to texture the surfaces of biological implant materials. The materials investigated included 316 stainless steel; titanium-6% aluminum, 4% vanadium; cobalt-20% chromium, 15% tungsten; cobalt-35% nickel, 20% chromium, 10% molybdenum; polytetrafluoroethylene; polyoxymethylene; silicone and polyurethane copolymer; 32%-carbon-impregnated polyolefin; segmented polyurethane; silicone rubber; and alumina. Scanning electron microscopy was used to determine surface morphology changes of all materials after ion-texturing. Electron spectroscopy for chemical analysis was used to determine the effects of ion-texturing on the surface chemical composition of some polymers. Liquid contact angle data were obtained for ion-textured and untextured polymer samples. Results of tensile and fatigue tests of ion-textured metal alloys are presented. Preliminary data of tissue response to ion-textured surfaces of some metals, polytetrafluoroethylene, alumina, and segmented polyurethane have been obtained.
Weigand, A. J.↗