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At least 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

The characterization of widespread fatigue damage in fuselage structure

The characteristics of widespread fatigue damage (WSFD) in fuselage riveted structure were established by detailed nondestructive and destructive examinations of fatigue damage contained in a full size fuselage test article. The objectives of this were to establish an experimental data base for validating emerging WSFD analytical prediction methodology and to identify first order effects that contribute to fatigue crack initiation and growth. Detailed examinations were performed on a test panel containing four bays of a riveted lap splice joint. The panel was removed from a full scale fuselage test article after receiving 60,000 full pressurization cycles. The results of in situ examinations document the progression of fuselage skin fatigue crack growth through crack linkup. Detailed tear down examinations and fractography of the lap splice joint region revealed fatigue crack initiation sites, crack morphology, and crack linkup geometry. From this large data base, distributions of crack size and locations are presented and discussions of operative damage mechanisms are offered.

Piascik, Robert S.↗
NASA NTRS2009

Recent Shuttle Post Flight MMOD Inspection Highlights

Post flight inspections on the Space Shuttle Atlantis conducted after the STS-11.5 mission revealed a 0.11 inch (2.8 mm) hole in the outer face sheet of the starboard payload bay door radiator panel #4. The payload bay door radiators in this region are 0.5 inch (12.7 mm) thick aluminum honeycomb with 0.011 in (0.279 mm) thick aluminum face sheets topped with 0.005 in (0.127 mm) silver-Teflon tape. Inner face sheet damage included a 0.267 in (6.78 mm) long through crack with measureable deformation in the area of 0.2 in (5.1 mm). There was also a 0.031 in (0.787 nun) diameter hole in the rear face sheet. A large approximately l in (25 mm) diameter region of honeycomb was also destroyed. Since the radiators are located on the inside of the shuttle payload bay doors which are closed during ascent and reentry, the damage could only have occurred during the on-orbit portion of the mission. During the August 2007 STS-118 mission to the International Space Station, a micro-meteoroid or orbital debris (MMOD) particle impacted and completely penetrated one of shuttle Endeavour's radiator panels and the underlying thermal control system (TCS) blanket, leaving deposits on (but no damage to) the payload bay door. While it is not unusual for shuttle orbiters to be impacted by small MMOD particles, the damage from this impact is larger than any previously seen on the shuttle radiator panels. One of the largest impacts ever observed on a crew module window occurred during the November 2008 STS-126 mission to the International Space Station. Damage to the window was documented by the crew on orbit. Post flight inspection revealed a 0.4 in (10.8 mm) crater in the window pane, with a depth of 0.03 in (0.76 mm). The window pane was replaced due to the damage caused by this impact. Analysis performed on residue contained in dental mold impressions taken of the site indicated that a meteoroid particle produced this large damage site. The post flight inspection after the subsequent mission, STS-119 in March of 2009, produced a large MMOD impact feature in a wing leading edge reinforced carbon-carbon panel. The crater measured 0.18 in (4.5 nun) in diameter and was nearly 0.037 in (0.93 nun) deep. The thickness of the silicon carbide coating that protects the carbon substrate is nominally 0.02 in (0.5 nun) to 0.04 in (1 mm), making this a significant impact into the RCC. The damage occurred on the upper surface of the panel, which experiences lower heat loads on re-entry. This poster will document the data collected from the impact sites and will include results of the Scanning Electron Microscope/Energy Dispersive X-ray (SEM/EDX) analysis. Evidence will be presented that suggests a source of the impacts.

Hyed, James L.↗
NASA NTRS2008

Characterization of Fatigue Damage for Bonded Composite Skin/Stringer Configurations

The fatigue damage was characterized in specimens which consisted of a tapered composite flange bonded onto a composite skin. Quasi-static tension tests were performed first to determine the failure load. Subsequently, tension fatigue tests were performed at 40%, 50%, 60% and 70% of the failure load to evaluate the debonding mechanisms. For four specimens, the cycling loading was stopped at intervals. Photographs of the polished specimen edges were taken under a light microscope to document the damage. At two diagonally opposite corners of the flange, a delamination appeared to initiate at the flange tip from a matrix crack in the top 45deg skin ply and propagated at the top 45deg/-45deg skin ply interface. At the other two diagonally opposite corners, a delamination running in the bondline initiated from a matrix crack in the adhesive pocket. In addition, two specimens were cut longitudinally into several sections. Micrographs revealed a more complex pattern inside the specimen where the two delamination patterns observed at the edges are present simultaneously across most of the width of the specimen. The observations suggest that a more sophisticated nondestructive evaluation technique is required to capture the complex damage pattern of matrix cracking and multi-level delaminations.

Paris, Isabelle↗
NASA NTRS1994

The characterization of widespread fatigue damage in fuselage structure

The characteristics of widespread fatigue damage (WSFD) in fuselage riveted structure were established by detailed nondestructive and destructive examinations of fatigue damage contained in a full size fuselage test article. The objectives of this work were to establish an experimental data base for validating emerging WSFD analytical prediction methodology and to identify first order effects that contribute to fatigue crack initiation and growth. Detailed examinations were performed on a test panel containing four bays of a riveted lap splice joint. The panel was removed from a full scale fuselage test article after receiving 60,000 full pressurization cycles. The results of in situ examinations document the progression of fuselage skin fatigue crack growth through crack linkup. Detailed tear down examinations and fractography of the lap splice joint region revealed fatigue crack initiation sites, crack morphology and crack linkup geometry. From this large data base, distributions of crack size and locations are presented and discussions of operative damage mechanisms are offered.

Piascik, Robert S.↗
NASA NTRS2019

Benchmarking Mixed Mode Failure in Progressive Damage and Failure Analysis Methods

The verification and validation of progressive-damage-analysis finite element methods are difficult but critical tasks to undertake during their development. Verification exercises assess whether a predictive analysis tool produces results that are consistent with the fundamental concepts and assumptions of the tool under evaluation. Ideally, closed-form analytical solutions can be derived for which method verification results can be compared. Problems selected for computational tool verification are often simple and isolate individual features of the tool. In the case of progressive damage finite element methods, verifications should be performed to evaluate the ability of the model to predict the initiation of damage and its growth through the finite element mesh under a variety of conditions. Mabson et al. proposed a test case of a unidirectional, fiber-reinforced plate with a center crack subjected to tensile loads to evaluate matrix crack propagation predictions. The problem was modeled using the Abaqus Hashin continuum damage mechanics (CDM) model for fiber-reinforced composites. Different combinations of matrix strengths and element sizes were used in the simulations, and the results were compared to a closed-form solution based on linear elastic fracture mechanics (LEFM). It was determined that the Abaqus CDM model could predict the LEFM solution of Mode I cracks only when the finite element mesh density met specific requirements based on the material properties. This paper presents closed-form LEFM solutions for a center notch mixed mode (CNMM) verification problem. Parametric finite element analyses were developed using progressive damage analysis methods of both the Discrete Damage Mechanics (DDM) and CDM classes. The progressive damage analysis methods applied in the analyses of the CNMM problem include CompDam and the Floating Node Method. Analyses were conducted with various mode mixities and element sizes to verify that the damage models were working as intended and to identify any limits of applicability.

Leone, Frank↗
DOE OSTI2022

Doping Metallic Grain Boundaries to Control Atomic Structure and Damage Tolerance (Final Report)

The interfaces between crystals, known as grain boundaries, often act as sites for crack and void nucleation during plastic deformation of metallic materials. While it is known that interfacial character and structural state can greatly influence this damage nucleation process, the current level of control over such details is extremely limited. The objective of this project was to obtain a fundamental understanding of how metallic grain boundary structure can be controlled through intelligent doping, with the idea of inducing planned grain boundary phases or complexions. The effect of complexion structure on dislocation accommodation mechanisms was studied, to improve the field’s understanding of damage nucleation at interfaces. While mechanical damage was the primary focus, the project showed that amorphous complexions can also improve a material’s resistance to radiation damage, providing a single materials design concept that can address multiple important technological areas. This research used a combination of computational, experimental, and characterization techniques to isolate and understand the importance of nanoscale grain boundary structure and interfacial chemistry. The fundamental insights provided by this project enable the creation of advanced engineering metals with improved damage tolerance.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A Fast, Accurate Prediction for System-Wide Damage Due to Dynamic Wind Loading

The complex relationship between photovoltaic (PV) hardware configurations, overall system dynamics, and turbulent aerodynamic phenomena generates highly unsteady, non-uniform loads that can lead to damaging instabilities. These effects may result in glass breakage, cell cracking, and structural failures in frames and mounting systems, even under moderate wind conditions. Addressing industry concerns about premature system failures in field conditions deemed survivable, our research aims to develop a fast and accurate predictive model for system damage. This model integrates configurable hardware choices with advanced simulation tools to represent the overall system-specific dynamics effectively. Using this model, we predict responses under varying weather conditions and hardware setups, translating these predictions into pre-trained surrogate models capable of accurately identifying failure risks and rapidly testing new system hardening measures. In this presentation, we will showcase preliminary results in capturing system dynamics through our customizable library of PV hardware configurations. Additionally, we will highlight how these new tools build upon PVade's established wind load modeling capabilities and foster the development of advanced AI/ML surrogates for improving system robustness.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1971

C-130: Results of center wing residual strength and crack propagation test program

Fourteen C-130 airplane center wings which had experienced from approximately 4,000 to 13,000 hours of flight service and its associated fatigue damage were tested to destruction, seven in upbending and seven in downbending. Six wings were tested directly for static residual strength in the fatigue-damaged condition as received from field service. The other eight wings were tested in crack propagation cyclic testing at a prescribed stress level for a maximum of 10,000 cycles. Then the stress level was reduced and testing was continued up to a maximum of 20,000 total cycles. Cyclic testing was performed with constant-amplitude stresses at a stress ratio of +0.1. Maximum cyclic skin stresses were approximately 18,000 psi. At the conclusion of cyclic testing, a static test to destruction was conducted to determine the residual strength of each fatigue-damaged specimen.

Reeder, F. L.↗
DOE OSTI2020

Solving Recent Challenges for Wrought Ni-Base Superalloys

This paper reviews the status of technology in design and manufacture of new wrought 21 polycrystalline Ni-base superalloys for critical engineering applications. There is a strong 22 motivation to develop new alloys that are capable of operating at higher temperatures to 23 realise improvements in thermal efficiency, which are necessary to achieve environmental 24 targets for reduced emissions of harmful green-house gases. From the aerospace sector, 25 the development of new powder metallurgy and ingot metallurgy alloys are discussed for 26 disk rotor and static applications. New compositions for powder metallurgy contain about 27 50-55% of gamma prime (γ') strengthening precipitates to ensure components operate 28 successfully at temperatures up to 788°C (1450°F). In contrast, new compositions for ingot 29 metallurgy aim to occupy a design space in temperature capability between Alloy 718 and 30 current powder alloys that are in-service, and show levels of γ' of about 30-44%. The focus 31 in developing these alloys was design for manufacturability. To complement the aerospace 32 developments, a review of work to understand the suitability of candidate alloys for multiple 33 applications in Advanced-Ultra Supercritical (AUSC) power plants has been undertaken by 34 Detrois, Jablonski and Hawk from the National Energy Technology Laboratory. In these 35 power plants, steam temperatures are required to reach 700-760°C. The common thread is 36 to develop alloys that demonstrate a combination of high temperature properties, which are 37 reliant on both the alloy composition and microstructure and can be produced readily at the 38 right price. For the AUSC applications, the emphasis is on high temperature strength, long 39 term creep life, phase stability, oxidation resistance and robust welding for fabrications. 40 Whereas for powder disk rotors in aircraft engines, the priority is enhanced resistance to 41 time dependent crack growth, phase stability and resistance to environmental damage, while 42 extending the current strength levels, which are shown by existing alloys, to higher 43 temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Post-hazard condition assessment of nuclear piping-equipment systems: Novel approach to feature extraction and deep learning

Over the past decade, the use of artificial intelligence techniques in the field of health-monitoring has gained significant interest, especially for structures such as building and bridges. However, applications to industrial systems such as equipment-piping systems in nuclear plants have not been explored. Here, in this paper, it is shown that the existing techniques developed for buildings and bridges cannot be extended directly to equipment-piping systems as the response of such systems is governed by multiple localized modes unlike that in buildings and bridges. This paper proposes a new approach that consists of three key aspects: (i) a novel vector of degradation-sensitive features extracted from measured data, (ii) using a deep Artificial Neural Network (ANN) for diagnosis of degradation location and degradation severity, and (iii) consideration of uncertainty in degradation severity when training the ANN. Degradation in piping-equipment systems can occur due to flow-accelerated erosion and corrosion. These locations can potentially exhibit damage such as localized yielding or initiation of cracking due to an external event such as an earthquake. Moreover, such locations can at times go undetected by current inspection techniques. Therefore, a robust framework is needed for detection of degradation after a seismic event. This manuscript proposes a proof-of-concept framework, which utilizes data collected from sensors to generate a deep ANN database for predicting degraded locations and severity in a piping-equipment system. Degradation severity is classified as minor, moderate, and severe. In the suggested methodology, a novel vector of degradation-sensitive features is extracted from the sensor data to train the ANN. A simple piping-equipment system is selected to demonstrate feature extraction as a means to simplify pattern recognition, explore the design and parameters of an ANN, and develop a sensor placement strategy. The effectiveness of the proposed framework is demonstrated on a realistic primary safety system of a two-loop nuclear reactor. It is shown that the proposed post-hazard condition assessment framework is able to detect degraded locations along with the severity levels, including minor degradation, with considerably higher accuracy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Multimetallic Layered Composites (MMLCs) for Rapid, Economical Advanced Reactor Deployment (Final Report)

This project focused on the development of multi-metallic layered composites (MMLCs) for advanced fission reactor technologies. There are many instances where one alloy or material simply cannot meet all the demands thrown at it by a reactor system, or cannot allow it to perform as strongly as one would like. Instead of focusing all our effort on developing one perfect alloy, we seek to leverage the design principle of “separation of functionality,” used in many other arenas in design, to boost performance beyond single alloys alone. One illustrative example shows the power of this approach for molten salt-cooled reactors: A three meter tall, three meter diameter reactor vessel made of Incoloy 800 was quoted at $\$$500k in 2018. A Hastelloy N vessel was quoted at $\$$5M. An MMLC vessel, in which a layer of Hastelloy N would be weld-overlaid onto Incoloy 800, was quoted at $\$$700k, and it would achieve the same performance. The potential economic gains of leveraging this approach are therefore substantial. At a minimum, each MMLC would contain one core structural layer and one coolant-facing corrosion-resistant layer. Sometimes, MMLCs required buffer layers, as the structural and corrosion-resistant layers were metallurgically incompatible. In other words, they didn’t always play nice, thus separating layers compatible with both functioned as intermediaries to keep the composite together. However, in doing so we inevitably produce new interfaces, where new issues can arise. Therefore, this project focused on what happens at these interfaces from a combination of high temperatures, irradiation, corrosion, and time. After all, a reactor makes money when it is operating, and outages of any kind erode its economic viability. First, we set out to experimentally prove that MMLCs for at least two advanced reactor systems can be made, today, in US domestic facilities. In this respect we were successful – one MMLC (a Ni-201/Incoloy 800H composite) was successfully made and drawn into two-inch coolant piping. Others were attempted, though new issues relating to cracking in vanadium layers for one and radiation damage performance of the corrosion-resistant layer in another prevented us from moving further in those specific arenas – these are engineering problems which deserve continued focus after this project. Additional experimental work focused on long-term corrosion testing of the outermost layers of the salt-cooled and liquid lead-cooled MMLC concepts, which would then be fed into predictions of how long the MMLCs could last. Next, computational (thermodynamics and atomistic) simulation studies studied how much we expect the interfaces to “blend,” due to the mixing action of neutron irradiation. This eats into both the margin for the structural layer of each MMLC, as dilution from the corrosion-resistant layer into the structural layer would decrease the total load-bearing capacity of an MMLC of finite size. On the other hand, dilution of the corrosion-resistant layer into the structural layer further reduced the margin of corrodible material, reducing the lifetime of the MMLC or necessitating extra thickness to be imparted to the MMLC to meet its functional requirements. Work here focused on irradiation-induced segregation to predict new phases which may embrittle the MMLCs, as well as quantifying irradiation-induced mixing at each interface. The results showed that mixing is expected, but it is both steady and therefore predictable, and not lifetime-limiting for most MMLC concepts – it simply has to be accounted for in calculations of reactor performance when utilizing an MMLC. Then, full-core simulations using the experimentally-derived corrosion data, the computationally discovered irradiation-induced mixing data (partially validated by experiment), and existing, benchmarked core designs for large and small sized reactor concepts (one salt-cooled, one lead-cooled) were conducted to quantify any expansion of reactor operating envelopes achieved by utilizing these MMLCs. This new framework, called REX (Reactor Envelope Expansion), incorporates a combination of core neutronics, thermal hydraulics, and the material performance data derived from this project to see how using an MMLC expands advanced fission reactor operating envelopes. It was discovered that in some cases, MMLC utilization does indeed increase the maximum operating temperatures and cycle lengths of reactor concepts, while in other cases it does not. Finally, our tech-to-market (T2M) strategy was not necessarily to create specific embodiments of MMLCs for immediate sale (because getting into the nuclear market is incredibly slow and laden with regulation, this is a long-term goal), but rather immediate stimulation of US industry using the design approach of MMLCs derived from this project. In this respect we were successful, as one of the PhD students funded on this project co-founded Allium Engineering, Inc., which created a stainless steel / low-alloy steel MMLC to function as chloride corrosion-resistant rebar for embedding into concrete structures. Allium Engineering continues to be successful, having recently opened their first factory as of this writing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Non-destructive structural characterization of graphite components using mechanical resonance and deep learning

As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.

36 MATERIALS SCIENCE↗
NASA NTRS1980

Microscope for high-temperature welding

Dark glass in eyepieces lets welder look at fine parts without eye damage. Previously welder had to repair barely visible crack without magnification, because necessary goggles kept eyes too far from microscope eyepieces.

Accountius, O. E.↗
NASA NTRS1984

Preliminary study of thermomechanical fatigue of polycrystalline MAR-M 200

Thermomechanical fatigue (TMF) experiments were conducted on polycrystalline MAR-M 200 over a cyclic temperature range of 500 to 1000 C. Inelastic strain ranges of 0.03 to 0.2 percent were imposed on the specimens. The TMF lives were found to be significantly shorter than isothermal low-cycle-fatigue (LCF) life at the maximum cycle temperature, and in-phase cycling was more damaging than out-of-phase cycling. Extensive crack tip oxidation appeared to play a role in promoting the severity of in-phase cycling. Carbide particle - matrix interface cracking was also observed after in-phase TMF cycling. The applicability of various life prediction models to the TMF results obtained was assessed. It was concluded that current life prediction models based on isothermal data as input must be modified to be applicable to the TMF results.

Bill, R. C.↗
NASA NTRS1983

Mechanics of composite materials: Recent advances; Proceedings of the Symposium, Virginia Polytechnic Institute and State University, Blacksburg, VA, August 16-19, 1982

The present conference on the mechanics of composites discusses microstructure's influence on particulate and short fiber composites' thermoelastic and transport properties, the elastoplastic deformation of composites, constitutive equations for viscoplastic composites, the plasticity and fatigue of metal matrix composites, laminate damping mechanisms, the micromechanical modeling of Kevlar/epoxy composites' time-dependent failure, the variational characterization of waves in composites, and computational methods for eigenvalue problems in composite design. Also discussed are the elastic response of laminates, elastic coupling nonlinear effects in unsymmetrical laminates, elasticity solutions for laminate problems having stress singularities, the mechanics of bimodular composite structures, the optimization of laminated plates and shells, NDE for laminates, the role of matrix cracking in the continuum constitutive behavior of a damaged composite ply, and the energy release rates of various microcracks in short fiber composites.

Hashin, Z.↗
NASA NTRS1985

Impact induced fracture in a laminated composite

Experimental data of the three-dimensional problem of impact of a flat strip by a spherical impactor are presented and interpreted qualitatively by comparison with a plane-strain numerical analysis of an infinitely wide plate impacted by a cylindrical impactor. The role of transverse shear stress in proximal and middle layer crack initiation is established. A detailed presentation of damage is provided with exact delamination zones. The basic conclusions drawn establish a basis for further research in understanding impact induced fracture in composites.

Joshi, S. P.↗
NASA NTRS1987

A fractographic investigation of the influence of stacking sequence on the strength of notched laminated composites

The fracture behavior of T300/5208 CFRP laminate panels with 12 different combinations of ply orientation and stacking sequence is investigated experimentally, using optical microscopy, SEM, and X-ray radiography to characterize the notch-tip damage zones and fracture surfaces of center-cracked tension specimens subjected to tensile loading at constant crosshead displacement rate 20 micron/s. The results are presented graphically and analyzed in detail. Significant differences in notched strength are found for different ply fiber orientations and stacking sequences; the laminates with few major delaminations had a greater percentage of fracture due to broken fibers and also higher notched strength.

Harris, Charles E.↗
NASA NTRS1991

Impact properties of three-dimensional braided graphite/epoxy composites

An experimental study of the response and damage of three-dimensional braided graphite/epoxy composite due to sub-perforation velocity impact was carried out in this research. Simply supported square plates were impacted with an instrumented impact pendulum and also a projectile fired by a gas gun. Hemispherical nose impactors of two different diameters, 12.7 mm and 25.4 mm, were used in the pendulum tests. In addition, static flexure tests were performed. Impact damage was assessed using X-radiography, and compression after impact tests. Damages involved in impacted braided panel are matrix cracking in resin pockets, separation of fiber tows, and fiber two breakage, mostly in fiber bundle crimp areas. A quasi-isotropic laminate was impact tested with pendulum for comparison of impact tolerance between the two composite systems.

Gong, J. C.↗