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At least 577 records · Page 32

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NASA NTRS1988

Elevated temperature crack growth

The problem of crack growth in hot path components such as combustor liners is complicated by several practical and theoretical considerations. The loading environment of such components involves high temperature levels and gradients that lead to considerations such as thermal stresses, crack closure, hold time, inelastic strains (both time dependent and independent), and Thermal Mechanical Fatigue (TMF). In general, a good understanding of the influence of these factors on crack growth was not obtained. At the same time, several nonlinear fracture mechanics parameters were suggested for such applications; however, most of the proposed methods were not tested for broad applications such as required for hot section components. It was the purpose of this program to evaluate proposed nonlinear methods by performing a thorough experimental and analytical study. The results illustrated that much progress was made in developing nonlinear methods.

Kim, K. S.↗

NASA NTRS1990

NASA airframe structural integrity program

NASA initiated a research program with the long-term objective of supporting the aerospace industry in addressing issues related to the aging of the commercial transport fleet. The program combines advanced fatigue crack growth prediction methodology with innovative nondestructive examination technology with the focus on multi-stage damage (MSD) at rivited connections. A fracture mechanics evaluation of the concept of pressure proof testing the fuselage to screen for MSD was completed. A successful laboratory demonstration of the ability of the thermal flux method to detect disbonds at rivited lap splice joints was conducted. All long-term program elements were initiated, and the plans for the methodology verification program are being coordinated with the airframe manufacturers.

Harris, Charles E.↗

NASA NTRS1990

Elevated temperature crack growth in advanced powder metallurgy aluminum alloys

Rapidly solidified Al-Fe-V-Si powder metallurgy alloy FVS0812 is among the most promising of the elevated temperature aluminum alloys developed in recent years. The ultra fine grain size and high volume fraction of thermally stable dispersoids enable the alloy to maintain tensile properties at elevated temperatures. In contrast, this alloy displays complex and potentially deleterious damage tolerant and time dependent fracture behavior that varies with temperature. J-Integral fracture mechanics were used to determine fracture toughness (K sub IC) and crack growth resistance (tearing modulus, T) of extruded FVS0812 as a function of temperature. The alloy exhibits high fracture properties at room temperature when tested in the LT orientation, due to extensive delamination of prior ribbon particle boundaries perpendicular to the crack front. Delamination results in a loss of through thickness constraint along the crack front, raising the critical stress intensity necessary for precrack initiation. The fracture toughness and tensile ductility of this alloy decrease with increasing temperature, with minima observed at 200 C. This behavior results from minima in the intrinsic toughness of the material, due to dynamic strain aging, and in the extent of prior particle boundary delaminations. At 200 C FVS0812 fails at K levels that are insufficient to cause through thickness delamination. As temperature increases beyond the minimum, strain aging is reduced and delamination returns. For the TL orientation, K (sub IC) decreased and T increased slightly with increasing temperature from 25 to 316 C. Fracture in the TL orientation is governed by prior particle boundary toughness; increased strain localization at these boundaries may result in lower toughness with increasing temperature. Preliminary results demonstrate a complex effect of loading rate on K (sub IC) and T at 175 C, and indicate that the combined effects of time dependent deformation, environment, and strain aging may play a role. Fractography showed that microvoid coalescence was the microscopic mode of fracture in FVS0812 under all testing conditions. However, the nature of the microvoids varied with test temperature and loading rate, and is complex for the fine grain and dipersoid sizes of FVS0812.

Porr, William C., Jr.↗

NASA NTRS1993

Multi-disciplinary coupling effects for integrated design of propulsion systems

Effective computational simulation procedures are described for modeling the inherent multi-disciplinary interactions which govern the accurate response of propulsion systems. Results are presented for propulsion system responses including multi-disciplinary coupling effects using coupled multi-discipline thermal, structural, and acoustic tailoring; an integrated system of multi-disciplinary simulators; coupled material behavior/fabrication process tailoring; sensitivities using a probabilistic simulator; and coupled materials, structures, fracture, and probabilistic behavior simulator. The results demonstrate that superior designs can be achieved if the analysis/tailoring methods account for the multi-disciplinary coupling effects. The coupling across disciplines can be used to develop an integrated coupled multi-discipline numerical propulsion system simulator.

Chamis, C. C.↗

NASA NTRS1993

Analysis of local delaminations caused by angle ply matrix cracks

Two different families of graphite/epoxy laminates with similar layups but different stacking sequences, (0,theta,-theta) sub s and (-theta/theta/0) sub s were analyzed using three-dimensional finite element analysis for theta = 15 and 30 degrees. Delaminations were modeled in the -theta/theta interface, bounded by a matrix crack and the stress free edge. The total strain energy release rate, G, along the delamination front was computed using three different techniques: the virtual crack closure technique (VCCT), the equivalent domain Integral (EDI) technique, and a global energy balance technique. The opening fracture mode component of the strain energy release rate, Gl, along the delamination front was also computed for various delamination lengths using VCCT. The effect of residual thermal and moisture stresses on G was evaluated.

Salpekar, Satish A.↗

DOE OSTI2024

A General Model for the Ductility of Intermetallics Applied to Fe-Co Alloys

The mechanical properties, specifically ductility, of high performing soft magnets such as Fe-Co alloys are a limiting factor to their broader use in a number of systems. The understanding of the mechanical robustness in these materials is currently insufficient to be able to support the growing interest in applications such as magnetic shielding or electric motors. Fe-Co alloys provide the highest commercially available magnetic saturation and high magnetic permeability but have very poor ductility. The addition of vanadium to these alloys has allowed for significant commercialization and some ductility improvements, but the fundamental reasons for the observed improvements are not well understood. In most published work on mechanical properties in these alloys, the precise chemistry of the alloys investigated, often a critical aspect of intermetallics, is not reported or controlled and thermal history is unclear. This work creates a ductility model that is sensitive to changes in chemistry and can predict relative strain to failure as well as brittle fracture mode for intermetallics and is applied to Fe-Co alloys. Through the application of density functional theory (DFT), this model identifies defect stabilities, anti-phase boundary (APB) energies, the energy necessary to cross-slip, and cleavage energies and combines them through energetic competition to determine a relative failure strain. The model correctly predicts ductility improvements with the addition of vanadium as well as the transition from intergranular to transgranular cleavage, though more precise experiments are necessary to appropriately validate the various improvements observed.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Tuning dispersity of linear polymers and polymeric brushes grown from nanoparticles by atom transfer radical polymerization

Molecular weight distribution imposes considerable influence on the properties of polymers, making it an important parameter, impacting morphology and structural behavior of polymeric materials. Atom transfer radical polymerization (ATRP) has established itself as a powerful tool to prepare polymers with predetermined molecular weight, preserved chain-end functionality, and low dispersity. More recently, ATRP has also been shown to provide a means to deliberately broaden molecular weight distributions, and, via retaining living chain-ends, to enable the formation of block copolymers with designed block dispersity, featuring new microstructures and potentially attractive properties. Here, similar methodologies have been developed to facilitate tuning of the dispersity of polymeric brushes grown from nanoparticles thus resulting in hybrid materials with enhanced fracture toughness and high inorganic content. Recent advances have given access to brush architectures comprised of uni- and bimodal block copolymers with unique morphologies along with interesting mechanical, thermal, and optical properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Directional Cooling-Induced Fracturing Westerly Granite Test Results

Directional Cooling-Induced Fracturing (DCIF) experiments were conducted on a short, cylindrical sample of Westerly granite (diameter = 4 inches, height ~ 2 inches). Liquid nitrogen was poured in a copper cup attached to the top of the sample, and the resulting acoustic emissions (AEs) and temperature changes on the surface of the sample were monitored. The obtained AEs were used to determine the microcracking source locations and amplitude, and the associated moment tensors. Included in this submission is an animation of the AEs, a graphic displaying the temperature changes, and the measured data.

15 GEOTHERMAL ENERGY↗

NASA NTRS1993

Advanced reinforcement systems for intermetallic applications

A 2-D axisymmetric model was employed to determine the magnitude of the radial, axial, and hoop stresses caused by the thermal expansion difference between fiber and matrix and which result from the fabrication temperature cycle. Finite element analysis was conducted for single fiber model systems based on SCS-6/Ti3Al+Nb and Al2O3/NiAl. The stress distribution due to the imposition of a graded intermediate layer for each system was determined and included variables of layer thickness and gradation in interlayer chemistry in order to vary the expansion gradient between fiber and matrix. Thermal cycling tests were conducted on sputter coated SCS-6 fibers selectively coated with Ti3Al+Nb, with and without an intermediate layer. Cracking of the Ti3Al+Nb layers was prevented by an interlayer based on Ti-TiN-Ti. The interlayer thickness appeared critical to its efficiency. Similarly, for the case of Al2O3/NiAl, an intermediate layer consisting of a Ni bond coat on the sapphire fiber followed by a graded Al2O3-NiAl layer did not crack when given a thermal excursion to 1100 C and then cooled to room temperature. Acoustic emission tests on single fiber specimens were unsuccessful in detecting load drops associated with the successive fracture of the fiber. For the SCS-6/Ti3Al system this was the result of several factors which included the matrix/fiber ratio and poor bonding of the matrix and fiber. In the case of the Al2O3/NiAl system brittle failure of the NiAl matrix precluded fiber breakdown during tensile loading.

Merrick, Howard F.↗

NASA NTRS2001

Dynamic Response Assessment for the MEMS Accelerometer Under Severe Shock Loads

NASA Goddard Space Flight Center (GSFC) has evaluated the dynamic response of a commercial-off-the-shelf (COTS) microelectromechanical systems (MEMS) device made by Analog Device, Inc. The device is designated as ADXL250 and is designed mainly for sensing dynamic acceleration. It is also used to measure the tilting angle of any system or component from its original level position. The device has been in commercial use (e.g., in automobile airbag deployment system as a dual-axial accelerometer and in the electronic game play-station as a tilting sensor) with success, but NASA needs an in-depth assessment of its performance under severe dynamic shock environments. It was realized while planning this evaluation task that two assessments would be beneficial to NASA's missions: (1) severe dynamic shock response under nominal thermal environments; and (2) general dynamic performance under cryogenic environments. The first evaluation aims at obtaining a good understanding of its micromachined structure within a framework of brittle fracture dynamics, while the second evaluation focuses on the structure integrity under cryogenic temperature conditions. The information we gathered from the manufacturer indicated that the environmental stresses under NASA's evaluation program have been far beyond what the device has experienced with commercial applications, for which the device was designed. Thus NASA needs the outcome of this evaluation in order to make the selection for possible use for its missions. This paper provides details of the first evaluation the dynamic response under severe multi-axial single-pulse shock load. It was performed using finite element tools with nonlinear dynamics procedures.

Fan, Mark S.↗

NASA NTRS2003

Characterization of Al-Cu-Mg-Ag Alloy RX226-T8 Plate

Aluminum-copper-magnesium-silver (Al-Cu-Mg-Ag) alloys that were developed for thermal stability also offer attractive ambient temperature strength-toughness combinations, and therefore, can be considered for a broad range of airframe structural applications. The current study evaluated Al-Cu-Mg-Ag alloy RX226-T8 in plate gages and compared performance with sheet gage alloys of similar composition. Uniaxial tensile properties, plane strain initiation fracture toughness, and plane stress tearing resistance of RX226-T8 were examined at ambient temperature as a function of orientation and thickness location in the plate. Properties were measured near the surface and at the mid-plane of the plate. Tensile strengths were essentially isotropic, with variations in yield and ultimate tensile strengths of less than 2% as a function of orientation and through-thickness location. However, ductility varied by more than 15% with orientation. Fracture toughness was generally higher at the mid-plane and greater for the L-T orientation, although the differences were small near the surface of the plate. Metallurgical analysis indicated that the microstructure was primarily recrystallized with weak texture and was uniform through the plate with the exception of a fine-grained layer near the surface of the plate. Scanning electron microscope analysis revealed Al-Cu-Mg second phase particles which varied in composition and were primarily located on grain boundaries parallel to the rolling direction. Fractography of toughness specimens for both plate locations and orientations revealed that fracture occurred predominantly by transgranular microvoid coalescence. Introduction High-strength, low-density Al-Cu-Mg-Ag alloys were initially developed to replace conventional 2000 (Al-Cu-Mg) and 7000 (Al-Zn-Cu-Mg) series aluminum alloys for aircraft structural applications [1]. During the High Speed Civil Transport (HSCT) program, improvements in thermal stability were demonstrated for candidate aircraft wing and fuselage skin materials through the addition of silver to Al-Cu-Mg alloys based on Al 2519 chemistry [2]. Thermal stability of the resulting Al-Cu-Mg-Ag alloys, C415-T8 and C416-T8, was due to co-precipitation of the thermally stable . (AlCu) and ' (Al2Cu) strengthening phases [1-4]. The strength and toughness behavior was investigated for these alloys produced as 0.090-inch thick rolled sheet in the T8 condition and after various thermal exposures. The mechanical properties were shown to be competitive with conventional aircraft alloys, 2519-T8 and 2618-T8 [2]. During the Integral Airframe Structure (IAS) program, advanced aluminum alloys were examined for use in an integrally stiffened airframe structure where the skin and stiffeners would be machined from plate and extruded frames would be mechanically attached (see Figure 1) [5]. Advantages of integrally stiffened structure include reduced part count, and reduced assembly times compared to conventional built-up airframe structure. The near-surface properties of a thick plate are of significance for a machined integrally stiffened airframe structure since this represents the skin location. Properties measured at the mid-plane of the plate are more representative of the stiffener web. RX226 was developed to exploit strength-toughness improvements and thermal stability benefits of Al-Cu-Mg-Ag alloys in plate gages. This study evaluated the microstructure and properties of three gages of plate produced in the T8 condition.

Lach, Cynthia L.↗

NASA NTRS2004

Development and Testing of Ceramic Thermal Barrier Coatings

Ceramic thermal barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. Durability of the coating systems remains a critical issue with the ever-increasing temperature requirements. Thermal conductivity increase and coating degradation due to sintering and phase changes are known to be detrimental to coating performance. There is a need to characterize the coating behavior and temperature limits, in order to potentially take full advantage of the current coating capability, and also accurately assess the benefit gained from advanced coating development. In this study, thermal conductivity behavior and cyclic durability of plasma-sprayed ZrO2-8wt%Y2O3 thermal barrier coatings were evaluated under laser heat-flux simulated high temperature, large thermal gradient and thermal cycling conditions. The coating degradation and failure processes were assessed by real-time monitoring of the coating thermal conductivity under the test conditions. The ceramic coating crack propagation driving forces and resulting failure modes will be discussed in light of high temperature mechanical fatigue and fracture testing results.

Zhu, Dongming↗

NASA NTRS2011

Capacitor Test, Evaluation. and Modeling Within NASA Electronic Parts and Packaging (NEPP) Program. "Why Ceramic Capacitors Fracture During Manual Soldering and How to Avoid Failures"

Presentation discusses: (1) Why Multi-Layer Ceramic Capacitors(MLCCs) crack during manual soldering? Workmanship and parts issues. (2) Do existing qualification requirements assure crack-free soldering? MIL-spec Thermal Shock (TS) testing. MIL-spec Resistance to Soldering Heat (RSH) test. (3) What test can assure reliable soldering? Mechanical characteristics of ceramics. Comparison of three TS techniques: LND, TSD, and IWT. (4) Simulation of TS conditions.

Teverovsky, Alexander↗

DOE OSTI2024

Development of Ti 3 SiC 2 MAX phase tubular structures for solar receiver applications

Solar receiver tubes are key components of concentrating solar-thermal power (CSP) systems that harvest solar energy. For better efficiency, the Gen3 CSP receivers, which collect heat into a heat transfer fluid, require a temperature exceeding 700 °C during operation and need to perform under extreme conditions of high temperature and high thermal stress. Operators are seeking CSP designs using new high-temperature structural materials with high thermal conductivity and high creep resistance to achieve a design life of 30 years and thus help recover the plant capital cost sooner. MAX phase materials, which consist of an early transition metal element, an A-group element, and carbon or nitrogen, are expected to exhibit high creep resistance as well as high fracture toughness. Here, in this paper, we describe fabricating both (1) dense Ti 3 SiC 2 MAX phase disks and (2) short-length tubes using field-assisted sintering technology (FAST). First, the disk samples that we fabricated are fully dense and contain ≈90 % Ti 3 SiC 2 MAX phase materials and ≈10 % TiC phase materials. We determined a flexure strength of 519 ± 32 MPa by conducting a four-point bending test at room temperature with rectangular bar samples of ≈100 % density. The thermal conductivity of the Ti 3 SiC 2 MAX phase samples, measured by light flashing analysis, decreases linearly from a value of 41 W . m -1 . K -1 at room temperature to a value of 36 W . m -1 . K -1 at 650 °C. A solar reflectance measurement of the Ti 3 SiC 2 MAX phase revealed that, temperature increases from 400 to 1400 °C, thermal emittance increases from 0.39 to 0.49, while selectivity decreases from 1.8 to 1.4, respectively. Whereas the surface oxidized MAX phase samples after 100 h exposure to air at 1000 °C exhibit that of SiC. Next, we discuss fabrication of the crack-free Ti 3 SiC 2 MAX phase tubular structures accomplished by using FAST processing in graphite bedding. A Ti 3 SiC 2 MAX phase content of > 95 % with traceable ≈3% remaining TiC phase and ≈15 % porosity were demonstrated after high-temperature annealing. An average fracture strength of ≈250 MPa was determined with Ti 3 SiC 2 MAX phase tubes of ≈85 % density by diametral compression testing at room temperature. Our work demonstrated that using FAST processing to produce Ti 3 SiC 2 MAX phase tubular structures for CSP receiver applications is a viable approach.

14 SOLAR ENERGY↗

DOE OSTI2023

Fracture of PC and PMMA cylinders in the Taylor tests

The present paper analyzes failure observed in polymer rods collided with a steel anvil under the Taylor cylinder impact experiments. The experimental and numerical analysis demonstrates that association of the failure patterns with the loading mode depends on the rod material. Two materials are considered in the paper, specifically, polymethylmethacrylate (PMMA) and polycarbonate (PC). Damage in PMMA rods at the Taylor tests is shown to be dominated by the shear load resulting in plastic deformation. In contrast, the major mechanism of damage in PC rods is governed by omni-directional (pressure) mode of load. Analysis of the damage in sections of the rods associated with the glass transition is also addressed in the present theoretical study. Failure in these polymers follows the traditional fracture wave mechanism for brittle glass-type materials due to load in the corresponding mode. Numerical analysis employs a two-phase model with improved inter-phase thermal balance accounting for the inter-phase mass, momentum, and heat exchanges during the glass phase transition, while damage being accumulated in time. In conclusion, the simulation results demonstrate a good correlation with the experimental results.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Simulation of Chilled-water Injection at EGS Collab Testbed 2 using the GEOS simulation framework

This work seeks to model the chilled-water injection that occurred at EGS Collab Testbed 2 as part of experiment 3, using the open-source GEOS simulation framework. Modeling of this process, previously conducted using STOMP-GT, confirmed that thermal breakthrough was expected to occur during the chill water injection and may have been masked by strong Joule-Thompsons effects induced by large pressure drops between the fractures and the production wells. Building a GEOS numerical model of this process will allow to include additional physics. In fact, GEOS can model fully coupled thermo-poromechanical processes in fractured porous media and can be employed to model the process of artificially enhancing rock permeability by hydraulically fracturing the rocks. For example, the GEOS model could help understanding the dynamic nature of the EGS collab experiment 3 flow system. Since the limited time and resources do not allow for an extensive study, the focus is on building a baseline model of this process. As such, the main outcomes of this modelling efforts are listed below.

15 GEOTHERMAL ENERGY↗

NASA NTRS1987

Composite structural materials

The development and application of composite materials to aerospace vehicle structures which began in the mid 1960's has now progressed to the point where what can be considered entire airframes are being designed and built using composites. Issues related to the fabrication of non-resin matrix composites and the micro, mezzo and macromechanics of thermoplastic and metal matrix composites are emphasized. Several research efforts are presented. They are entitled: (1) The effects of chemical vapor deposition and thermal treatments on the properties of pitch-based carbon fiber; (2) Inelastic deformation of metal matrix laminates; (3) Analysis of fatigue damage in fibrous MMC laminates; (4) Delamination fracture toughness in thermoplastic matrix composites; (5) Numerical investigation of the microhardness of composite fracture; and (6) General beam theory for composite structures.

Loewy, Robert G.↗

NASA NTRS1988

Flexible backbone aromatic polyimide adhesives

Continuing research at Langley Research Center on the synthesis and development of new inexpensive flexible aromatic polyimides as adhesives has resulted in a material identified as LARC-F-SO2 with similarities to polyimidesulfone, PISO2, and other flexible backbone polyimides recently reported by Progar and St. Clair. Also prepared and evaluated was an endcapped version of PISO2. These two polymers were compared with LARC-TPI and LARC-STPI, polyimides research in our laboratory and reported in the literature. The adhesive evaluation, primarily based on lap shear strength (LSS) tests at RT, 177 C and 204 C, involved preparing adhesive tapes, conducting bonding studies and exposing lap shear specimens to 204 C air for up to 1000 hrs and to a 72-hour water boil. The type of adhesive failure as well as the Tg was determined for the fractured specimens. The results indicate that LARC-TPI provides the highest LSSs. LARC-F-SO2, LARC-TPI and LARC-STPI all retain their strengths after thermal exposure for 1000 hrs and PISO2 retains greater than 80 percent of its control strengths. After a 72-hr water boil exposure, most of the four adhesive systems showed reduced strengths for all test temperatures although still retaining a high percentage of their original strength (greater than 60 percent) except for one case. The predominant failure type was cohesive with no significant change in the Tgs.

Progar, Donald J.↗