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At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
NASA NTRS1972

An investigation of strain cycling behavior of 7075-T6 aluminum under combined state of strain: The effects of out-of-phase, biaxial strain cycling on low cycle fatigue

The effect of out-of-phase strain cycling on the low cycle fatigue of biaxially loaded specimens is discussed. A method to apply phase angles between two strains imposed in two different directions was developed. The data and the proposed theoretical analysis are part of a research program on biaxial strain cycling effect on fatigue life of structural materials.

Zamrik, S. Y.↗
NASA NTRS1987

Fatigue-Testing Apparatus for Metal Matrix Composites

Thermal and mechanical load cycling simulated in realistic fatigue tests. Efficient joining of metal matrix composite components to supporting structures is major concern facing users of these materials. Lewis Research Center designed and developed two thermal/mechancical fatigue test facilities, one to test metal matrix composite specimens and another to test compostite/metal attachment bond joints. Thermal/mechanical fatigue facility designed for testing metal matrix composites permits specimen-temperature excursions with controlled heating and loading rates. Second facility designed to test composite/metal attachment bond joints and to permit heating to maximum temperature of 1,400oC (760oC) within 10 min and cooling to 300oF (150oC) within 3 min. Facility has unique capabilities not found in other laboratories.

Westfall, Leonard J.↗
NASA NTRS1981

Prediction of fatigue-crack growth under variableamplitude and spectrum loading using a closure model

An existing analytical crack closure model was used to study crack growth under various load histories. The model was based on a concept like the Dugdale model, but modified to leave plastically deformed material in the wake of the advancing crack tip. The model was used to correlate crack growth rates under constant amplitude loading, and to predict crack growth under variable amplitude and aircraft spectrum loading on 2219-T851 aluminum alloy sheet material. The predicted crack growth lives agreed well with experimental data. For 80 crack growth tests subjected to various load histories, the ratio of predicted-to-experimental lives (N(P)/n(T)) ranged from 0.5 to 1.8. The mean value of N(P)/N(T) was 0.97 and the standard deviation was 0.27.

Newman, J. C., Jr.↗
NASA NTRS2002

Superfinished Surfaces for Power Transfer Systems Improvement

The continuous demands for high performance and lightweight power train systems resulted in requirements for higher power density gearing systems. However, increasing the load bearing capacity of the gear teeth, without increasing size, places stringent requirements upon metallurgy, dimensional control, and surface finish of the final products. In order to operate the mating parts near the upper bounds of their theoretical design envelope, manufacturing processes are required that are capable of improving the fatigue life and load bearing capacity of precision parts, while producing the required geometric accuracy. Results of the recent experimental studies indicate that the super finishing process is able to achieve these goals. This paper will review the results of our continuing evaluation of the super finish process as applied to aerospace gearing. Two separate evaluations were performed on gears to examine the effects of super finishing on resistance to both pitting and contact fatigue. For the reported experiments, both conventional and super finished test gears were simultaneously manufactured using the same process and the same heat lot of materials. This paper will also provide a brief description of the manufacturing technology used to achieve the results and will compare the results with other published data. In addition, this paper presents a couple of off-the-shelf manufacturing technologies that have been successfully used to super finish test specimens and will provide a glimpse of other emerging super finishing technologies. This is a US Army Manufacturing Technology project. The project was sponsored by the Aviation and Missiles Command (AMCOM) and was being managed and conducted by IIT Research Institute.

Niskanen, Paul↗
NASA NTRS2005

Probabilistic Fracture Mechanics Analysis of the Orbiter's LH2 Feedline Flowliner

Work performed by Southwest Research Institute (SwRI) as part of an Independent Technical Assessment (ITA) for the NASA Engineering and Safety Center (NESC) is summarized. The ITA goal was to establish a flight rationale in light of a history of fatigue cracking due to flow induced vibrations in the feedline flowliners that supply liquid hydrogen to the space shuttle main engines. Prior deterministic analyses using worst-case assumptions predicted failure in a single flight. The current work formulated statistical models for dynamic loading and cryogenic fatigue crack growth properties, instead of using worst-case assumptions. Weight function solutions for bivariant stressing were developed to determine accurate crack "driving-forces". Monte Carlo simulations showed that low flowliner probabilities of failure (POF = 0.001 to 0.0001) are achievable, provided pre-flight inspections for cracks are performed with adequate probability of detection (POD)-specifically, 20/75 mils with 50%/99% POD. Measurements to confirm assumed POD curves are recommended. Since the computed POFs are very sensitive to the cyclic loads/stresses and the analysis of strain gage data revealed inconsistencies with the previous assumption of a single dominant vibrant mode, further work to reconcile this difference is recommended. It is possible that the unaccounted vibrational modes in the flight spectra could increase the computed POFs.

Bonacuse, Peter J.↗
NASA NTRS1996

Durability and Damage Tolerance of High Temperature Polymeric Composites

Modern durability and damage tolerance predictions for composite material systems rely on accurate estimates of the local stress and material states for each of the constituents, as well as the manner in which the constituents interact. In this work, an number of approaches to estimating the stress states and interactions are developed. First, an elasticity solution is presented for the problem of a penny-shaped crack in an N-phase composite material system opened by a prescribed normal pressure. The stress state around such a crack is then used to estimate the stress concentrations due to adjacent fiber fractures in composite materials. The resulting stress concentrations are then used to estimate the tensile strength of the composite. The predicted results are compared with experimental values. In addition, a cumulative damage model for fatigue is presented. Modifications to the model are made to include the effects of variable amplitude loading. These modifications are based upon the use of remaining strength as a damage metric and the definition of an equivalent generalized time. The model is initially validated using results from the literature. Also, experimental data from APC-2 laminates and IM7/K3B laminates are used in the model. The use of such data for notched laminates requires the use of an effective hole size, which is calculated based upon strain distribution measurements. Measured remaining strengths after fatigue loading are compared with the predicted values for specimens fatigued at room temperature and 350 F (177 C).

Case, Scott W.↗
NASA NTRS2001

Transient Reliability Analysis Capability Developed for CARES/Life

The CARES/Life software developed at the NASA Glenn Research Center provides a general-purpose design tool that predicts the probability of the failure of a ceramic component as a function of its time in service. This award-winning software has been widely used by U.S. industry to establish the reliability and life of a brittle material (e.g., ceramic, intermetallic, and graphite) structures in a wide variety of 21st century applications.Present capabilities of the NASA CARES/Life code include probabilistic life prediction of ceramic components subjected to fast fracture, slow crack growth (stress corrosion), and cyclic fatigue failure modes. Currently, this code can compute the time-dependent reliability of ceramic structures subjected to simple time-dependent loading. For example, in slow crack growth failure conditions CARES/Life can handle sustained and linearly increasing time-dependent loads, whereas in cyclic fatigue applications various types of repetitive constant-amplitude loads can be accounted for. However, in real applications applied loads are rarely that simple but vary with time in more complex ways such as engine startup, shutdown, and dynamic and vibrational loads. In addition, when a given component is subjected to transient environmental and or thermal conditions, the material properties also vary with time. A methodology has now been developed to allow the CARES/Life computer code to perform reliability analysis of ceramic components undergoing transient thermal and mechanical loading. This means that CARES/Life will be able to analyze finite element models of ceramic components that simulate dynamic engine operating conditions. The methodology developed is generalized to account for material property variation (on strength distribution and fatigue) as a function of temperature. This allows CARES/Life to analyze components undergoing rapid temperature change in other words, components undergoing thermal shock. In addition, the capability has been developed to perform reliability analysis for components that undergo proof testing involving transient loads. This methodology was developed for environmentally assisted crack growth (crack growth as a function of time and loading), but it will be extended to account for cyclic fatigue (crack growth as a function of load cycles) as well.

Nemeth, Noel N.↗
NASA NTRS1992

Damage mechanisms in bithermal and thermomechanical fatigue of Haynes 188

Post failure fractographic and metallographic studies were conducted on Haynes 188 specimens fatigued under bithermal and thermomechanical loading conditions between 316 and 760 C. Bithermal fatigue specimens examined included those tested under high strain rate in-phase and out-phase, tensile creep in-phase, and compressive creep out-of-phase loading conditions. Specimens tested under in-phase and out-of-phase thermomechanical fatigue were also examined. The nature of failure mode (transgrandular versus intergranular), the topography of the fracture surface, and the roles of oxidation and metallurgical changes were studied for each type of bithermal and thermomechanical test.

Kalluri, Sreeramesh↗
NASA NTRS2005

High Speed Research Program Sonic Fatigue

The objective of this sonic fatigue summary is to provide major findings and technical results of studies, initiated in 1994, to assess sonic fatigue behavior of structure that is being considered for the High Speed Civil Transport (HSCT). High Speed Research (HSR) program objectives in the area of sonic fatigue were to predict inlet, exhaust and boundary layer acoustic loads; measure high cycle fatigue data for materials developed during the HSR program; develop advanced sonic fatigue calculation methods to reduce required conservatism in airframe designs; develop damping techniques for sonic fatigue reduction where weight effective; develop wing and fuselage sonic fatigue design requirements; and perform sonic fatigue analyses on HSCT structural concepts to provide guidance to design teams. All goals were partially achieved, but none were completed due to the premature conclusion of the HSR program. A summary of major program findings and recommendations for continued effort are included in the report.

Rizzi, Stephen A.↗
NASA NTRS1982

Fatigue of graphite/epoxy /0/90/45/-45/s laminates under dual stress levels

A model for the prediction of loading sequence effects on the statistical distribution of fatigue life and residual strength in composite materials is generalized and applied to (0/90/45/-45)s graphite/epoxy laminates. Load sequence effects are found to be caused by both the difference in residual strength when failure occurs (boundary effect) and the effect of previously applied loads (memory effect). The model allows the isolation of these two effects, and the estimation of memory effect magnitudes under dual fatigue loading levels. It is shown that the material memory effect is insignificant, and that correlations between predictions of the number of early failures agree with the verification tests, as do predictions of fatigue life and residual strength degradation under dual stress levels.

Yang, J. N.↗
NASA NTRS1992

Finite-element analyses and fracture simulation in thin-sheet aluminum alloy

A two-dimensional, elastic-plastic finite-element analysis was used with a critical crack-tip-opening angle (CTOA) fracture criterion to model stable crack growth in thin-sheet 2024-T3 aluminum alloy under monotonic loading after precracking at different cyclic stress levels. Tests were conducted on three types of specimens: middle-crack, three-hole-crack and blunt-notch tensile specimens. An experiment technique was developed to measure CTOA during crack growth initiation and stable tearing using a high-resolution video camera and recorder. Crack front shapes were also measured during initiation and stable tearing using a fatigue marker-load technique. Three-dimensional elastic-plastic finite-element analyses of these crack shapes for stationary cracks were conducted to study the crack-front opening displacements. Predicted load against crack extension on middle-crack tension specimens agreed well with test results even for large-scale plastic deformations. The analyses were able to predict the effects of specimen size and precracking stress history on stable tearing. Predicted load against load-line displacements agreed well with test results up to maximum load bu the analyses tended to overpredict displacements as crack grew beyond the maximum load under displacement-controlled conditions. During the initiation phase, the measured CTOA values were high but decreased and remained nearly constant after a small amount of stable tearing. The constant value of CTOA agree well with the calculated value from the finite-element analysis. The larger CTOA values measured at the sheet surface during the initiation phase may be associated with the crack tunneling observed in the tests. Three-dimensional analyses for nonstraight crack fronts predicted much higher displacements near the free surface than in the interior.

Newman, J. C., Jr.↗
NASA NTRS1980

Research on graphite reinforced glass matrix composites

High levels of mechanical performance in tension, flexure, fatigue, and creep loading situations of graphite fiber reinforced glass matrix composites are discussed. At test temperatures of up to 813 K it was found that the major limiting factor was the oxidative instability of the reinforcing graphite fibers. Particular points to note include the following: (1) a wide variety of graphite fibers were found to be comparable with the glass matrix composite fabrication process; (2) choice of fiber, to a large extent, controlled resultant composite performance; (3) composite fatigue performance was found to be excellent at both 300 K and 703 K; (4) composite creep and stress rupture at temperatures of up to 813 K was limited by the oxidative stability of the fiber; (5) exceptionally low values of composite thermal expansion coefficient were attributable to the dimensional stability of both matrix and fiber; and (6) component fabricability was demonstrated through the hot pressing of hot sections and brazing using glass and metal joining phases.

Prewo, K. M.↗
NASA NTRS2002

Ultrasonic Characterization of Fatigue Cracks in Composite Materials

Microcracking in composite structures due to combined fatigue and cryogenic loading can cause leakage and failure of the structure and can be difficult to detect in-service. In aerospace systems, these leaks may lead to loss of pressure/propellant, increased risk of explosion and possible cryo-pumping. The success of nondestructive evaluation to detect intra-ply microcracking in unlined pressure vessels fabricated from composite materials is critical to the use of composite structures in future space systems. The work presented herein characterizes measurements of intraply fatigue cracking through the thickness of laminated composite material by means of correlation with ultrasonic resonance. Resonant ultrasound spectroscopy provides measurements which are sensitive to both the microscopic and macroscopic properties of the test article. Elastic moduli, acoustic attenuation, and geometry can all be probed. The approach is based on the premise of half-wavelength resonance. The method injects a broadband ultrasonic wave into the test structure using a swept frequency technique. This method provides dramatically increased energy input into the test article, as compared to conventional pulsed ultrasonics. This relative energy increase improves the ability to measure finer details in the materials characterization, such as microcracking and porosity. As the microcrack density increases, more interactions occur with the higher frequency (small wavelength) components of the signal train causing the spectrum to shift toward lower frequencies. Several methods are under investigation to correlate the degree of microcracking from resonance ultrasound measurements on composite test articles including self organizing neural networks, chemometric techniques used in optical spectroscopy and other clustering algorithms.

Workman, Gary L.↗
NASA NTRS2001

Skin, Stringer, and Fastener Loads in Buckled Fuselage Panels

The results of a numerical study to assess the effect of skin buckling on the internal load distribution in a stiffened fuselage panel, with and without longitudinal cracks, are presented. In addition, the impact of changes in the internal loads on the fatigue life and residual strength of a fuselage panel is assessed. A generic narrow-body fuselage panel is considered. The entire panel is modeled using shell elements and considerable detail is included to represent the geometric-nonlinear response of the buckled skin, cross section deformation of the stiffening components, and details of the skin-string attachment with discrete fasteners. Results are presented for a fixed internal pressure and various combinations of axial tension or compression loads. Results illustrating the effect of skin buckling on the stress distribution in the skin and stringer, and fastener loads are presented. Results are presented for the pristine structure, and for cases where damage is introduced in the form of a longitudinal crack adjacent to the stringer, or failed fastener elements. The results indicate that axial compression loads and skin buckling can have a significant effect on the circumferential stress in the skin, and fastener loads, which will influence damage initiation, and a comparable effect on stress intensity factors for cases with cracks. The effects on stress intensity factors will influence damage propagation rates and the residual strength of the panel.

Young, Richard D.↗
NASA NTRS1991

Computational simulation of acoustic fatigue for hot composite structures

Predictive methods/computer codes for the computational simulation of acoustic fatigue resistance of hot composite structures subjected to acoustic excitation emanating from an adjacent vibrating component are discussed. Select codes developed over the past two decades at the NASA Lewis Research Center are used. The codes include computation of acoustic noise generated from a vibrating component, degradation in material properties of a composite laminate at use temperature, dynamic response of acoustically excited hot multilayered composite structure, degradation in the first ply strength of the excited structure due to acoustic loading, and acoustic fatigue resistance of the excited structure, including the propulsion environment. Effects of the laminate lay-up and environment on the acoustic fatigue life are evaluated. The results show that, by keeping the angled plies on the outer surface of the laminate, a substantial increase in the acoustic fatigue life is obtained. The effect of environment (temperature and moisture) is to relieve the residual stresses leading to an increase in the acoustic fatigue life of the excited panel.

Singhal, Surendra N.↗
NASA NTRS1942

Improvement of fatigue life of an aluminum alloy by overstressing

Fatigue tests were made on some 1.375-inch-diameter and 0.300-inch diameter specimens of a 17S-T aluminum alloy rod. One test of a large specimen was run continuously to failure at a maximum stress of 22,000 pounds per square inch. In two other tests of large specimens, thin surface layers were removed periodically until failure occurred. The same nominal maximum stress of 22,000 pounds per square inch was used throughout the two tests and the load on the fatigue machine was lowered accordingly after the removal of each surface layer. As each test progressed the stress in the metal of the final surface area therefore was increased after the removal of each surface layer. Because of the stresses used, this metal was overstressed, that is, stressed above its endurance limit. All the remaining specimens were subjected to similar over- stressing conditions but no metal was removed and a low initial stress was increased periodically to a final maximum value of 22,000 pounds per square inch as each test progressed. It was found that the fatigue resistance of 17S-T aluminum alloy can be increased by moderate overstressing. Apparently the increase in fatigue lift obtained in the tests of specimens from which layers were removed was the result of overstressing rather than from the removal of damaged surface layers.

STRICKLEY G W↗