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At least 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

A Mixed-Mode I/II Fracture Criterion and Its Application in Crack Growth Predictions

A crack tip opening displacement (CTOD)-based, mixed mode fracture criterion is developed for predicting the onset and direction of crack growth. The criterion postulates that crack growth occurs in either the Mode I or Mode II direction, depending on whether the maximum in either the opening or the shear component of CTOD, measured at a specified distance behind the crack tip, attains a critical value. For crack growth direction prediction, the proposed CTOD criterion is shown to be equivalent to seven commonly used crack growth criteria under linearly elastic and asymptotic conditions. Under elastic-plastic conditions the CTOD criterion's prediction of the dependence of the crack growth direction on the crack-up mode mixity is in excellent agreement with the Arcan test results. Furthermore, the CTOD criterion correctly predicts the existence of a crack growth transition from mode I to mode II as the mode mixity approaches the mode II loading condition. The proposed CTOD criterion has been implemented in finite element crack growth simulation codes Z1P2DL and FRANC2DL to predict the crack growth paths in (a) a modified Arcan test specimen and fixture made of AL 2024-T34 and (b) a double cantilever beam (DCB) specimen made of AL 7050. A series of crack growth simulations have been carried out for the crack growth tests in the Arcan and DCB specimens and the results further demonstrate the applicability of the mixed mode CTOD fracture criterion crack growth predictions and residual strength analyses for airframe materials.

Sutton, Michael A.↗
NASA NTRS1999

Fracture Mechanics of Thin, Cracked Plates Under Tension, Bending and Out-of-Plane Shear Loading

Cracks in the skin of aircraft fuselages or other shell structures can be subjected to very complex stress states, resulting in mixed-mode fracture conditions. For example, a crack running along a stringer in a pressurized fuselage will be subject to the usual in-plane tension stresses (Mode-I) along with out-of-plane tearing stresses (Mode-III like). Crack growth and initiation in this case is correlated not only with the tensile or Mode-I stress intensity factor, K(sub I), but depends on a combination of parameters and on the history of crack growth. The stresses at the tip of a crack in a plate or shell are typically described in terms of either the small deflection Kirchhoff plate theory. However, real applications involve large deflections. We show, using the von-Karman theory, that the crack tip stress field derived on the basis of the small deflection theory is still valid for large deflections. We then give examples demonstrating the exact calculation of energy release rates and stress intensity factors for cracked plates loaded to large deflections. The crack tip fields calculated using the plate theories are an approximation to the actual three dimensional fields. Using three dimensional finite element analyses we have explored the relationship between the three dimensional elasticity theory and two dimensional plate theory results. The results show that for out-of-plane shear loading the three dimensional and Kirchhoff theory results coincide at distance greater than h/2 from the crack tip, where h/2 is the plate thickness. Inside this region, the distribution of stresses through the thickness can be very different from the plate theory predictions. We have also explored how the energy release rate varies as a function of crack length to plate thickness using the different theories. This is important in the implementation of fracture prediction methods using finite element analysis. Our experiments show that under certain conditions, during fatigue crack growth, the presence of out-of-plane shear loads induces a great deal of contact and friction on the crack surfaces, dramatically reducing crack growth rate. A series of experiments and a proposed computational approach for accounting for the friction is discussed.

Zehnder, Alan T.↗
NASA NTRS1999

Effect of Growth Rate on Elevated Temperature Plastic Flow and Room Temperature Fracture Toughness of Directionally Solidified NiAl-31Cr-3Mo

The eutectic system Ni-33Al-31Cr-3Mo was directionally solidified at rates ranging from 7.6 to 508 mm/h. Samples were examined for microstructure and alloy chemistry, compression tested at 1200 and 1300 K, and subjected to room temperature fracture toughness measurements. Lamellar eutectic grains were formed at 12.7 mm/h; however cellular structures with a radial eutectic pattern developed at faster growth rates. Elevated temperature compression testing between 10(exp -4) to 10(exp -7)/s did not reveal an optimum growth condition, nor did any single growth condition result in a significant fracture toughness advantage. The mechanical behavior, taken together, suggests that Ni-33Al-31Cr-3Mo grown at rates from 25.4 to 254 mm/h will have nominally equivalent properties.

Whittenberger, J. Daniel↗
NASA NTRS2000

Fracture Tests of Etched Components Using a Focused Ion Beam Machine

Many optical MEMS device designs involve large arrays of thin (0.5 to 1 micron components subjected to high stresses due to cyclic loading. These devices are fabricated from a variety of materials, and the properties strongly depend on size and processing. Our objective is to develop standard and convenient test methods that can be used to measure the properties of large numbers of witness samples, for every device we build. In this work we explore a variety of fracture test configurations for 0.5 micron thick silicon nitride membranes machined using the Reactive Ion Etching (RIE) process. Testing was completed using an FEI 620 dual focused ion beam milling machine. Static loads were applied using a probe. and dynamic loads were applied through a piezo-electric stack mounted at the base of the probe. Results from the tests are presented and compared, and application for predicting fracture probability of large arrays of devices are considered.

Kuhn, Jonathan, L.↗
NASA NTRS2000

Impact Delamination and Fracture in Aluminum/Acrylic Sandwich Plates

Impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F. Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

Liaw, Benjamin↗
NASA NTRS2000

Material Characterization for Ductile Fracture Prediction

The research summarized in this document provides valuable information for structural health evaluation of NASA infrastructure. Specifically, material properties are reported which will enable calibration of ductile fracture prediction methods for three high-toughness metallic materials and one aluminum alloy which can be found in various NASA facilities. The task of investigating these materials has also served to validate an overall methodology for ductile fracture prediction is currently being employed at NASA. In facilitating the ability to incorporate various materials into the prediction scheme, we have provided data to enable demonstration of the overall generality of the approach.

Hill, Michael R.↗
NASA NTRS2001

Progressive Fracture of Composite Structures

This report includes the results of a research in which the COmposite Durability STRuctural ANalysis (CODSTRAN) computational simulation capabilities were augmented and applied to various structures for demonstration of the new features and verification. The first chapter of this report provides an introduction to the computational simulation or virtual laboratory approach for the assessment of damage and fracture progression characteristics in composite structures. The second chapter outlines the details of the overall methodology used, including the failure criteria and the incremental/iterative loading procedure with the definitions of damage, fracture, and equilibrium states. The subsequent chapters each contain an augmented feature of the code and/or demonstration examples. All but one of the presented examples contains laminated composite structures with various fiber/matrix constituents. For each structure simulated, damage initiation and progression mechanisms are identified and the structural damage tolerance is quantified at various degradation stages. Many chapters contain the simulation of defective and defect free structures to evaluate the effects of existing defects on structural durability.

Minnetyan, Levon↗
NASA NTRS2002

Influence of Crack-Tip Configurations on the Fracture Response of 0.04-Inch Thick 2024-T3 Aluminum Alloy Sheet

A series of fracture tests were conducted on Middle-crack tension M(T) and compact tension C(T) specimens to determine the effects of specimen type, specimen width, notch tip sharpness and buckling on the fracture behavior of cracked thin sheet (0.04 inch thick) 2024-T3 aluminum alloy material. A series of M(T) specimens were tested with three notch tip configurations: (1) a fatigue pre-cracked notch, (2) a 0.010-inch-diameter wire electrical discharge machined (EDM) notch, and (3) a EDM notch sharpened with a razor blade. The test procedures are discussed and the experimental results for failure stress, load vs. crack extension and the material stress-strain response are reported.

Johnston, William M.↗
NASA NTRS2002

Cryogenic Fracture Toughness Improvement for the Super Lightweight Tank's Main Structural Alloy

Marshall Space Flight Center has developed a two-step (TS) artificial aging technique that can significantly enhance cryogenic fracture toughness and resistance to stress corrosion cracking (SCC) in aluminum-copper-lithium alloy 2195. The new TS aging treatment consists of exposures at 132 C (270 F)/20 hr + 138 C (280 F)/42 hr, which can be readily applied to flight hardware production. TS aging achieves the same yield strength levels as conventional aging, while providing much improved ductility in the short transverse direction. After TS aging, five previously rejected lots of alloy 2195 (lots 950M029B, 960M030F, 960M030J, 960M030K, and 960M030L) passed simulated service testing for use in the super lightweight tank program. Each lot exhibited higher fracture toughness at cryogenic temperature than at ambient temperature. Their SCC resistance was also enhanced. All SCC specimens passed the minimum 10-day requirement in 3.5-percent sodium chloride alternate immersion at a stress of 45 ksi. The SCC lives ranged from 57 to 83 days, with an average of 70 days.

Chen, P. S.↗
NASA NTRS2002

Artificial Aging Effects on Cryogenic Fracture Toughness of the Main Structural Alloy for the Super Lightweight Tank

In 1996, Marshall Space Flight Center developed a multistep heating rate-controlled (MSRC) aging technique that significantly enhanced cryogenic fracture toughness (CFT) and reduced the statistical spread of fracture toughness values in alloy 2195 by controlling the location and size of strengthening precipitate T1. However, it could not be readily applied to flight-related hardware production, primarily because large-scale production furnaces are unable to maintain a heating rate of 0.6 C (1 F)/hr. In August 1996, a new program was initiated to determine whether the MSRC aging treatment could be further modified to facilitate its implementation to flight hardware production. It was successfully redesigned into a simplified two-step aging treatment consisting of 132 C (270 F)/20 hr + 138 C (280 F)/40 hr. Results indicated that two-step aging can achieve the same yield strength levels as those produced by conventional aging while providing greatly improved ductility. Two-step aging proved to be very effective at enhancing CFT, enabling previously rejected materials to meet simulated service requirements. Cryogenic properties are improved by controlling T1 nucleation and growth so that they are promoted in the matrix and suppressed in the subgrain boundaries.

Chen, P. S.↗
NASA NTRS2003

Interface Finite Elements for the Analysis of Fracture Initiation and Progression

Progressive failure analyses (PFA) are important for the prediction of residual strength and damage tolerance of vehicle structures, and to predict the energy absorbing capability of vehicle structures under crash-type loads. Typically continuum damage mechanics (CDM) and fracture mechanics (FM) are the methods used for PFA. The method of interfacial damage mechanics (IDM) is used for PFA in this research. IDM has capabilities intermediate between CDM and FM, and is used to numerically model the initiation, growth, and arrest of cracks. IDM smooths the stress singularity at the crack tip, and is easily adaptable with other nonlinearties such as plasticity and material damage. IDM is implemented by user-defined interface elements in the ABAQUS/ Standard structural analysis software package. The structural components selected to demonstrate the effectiveness PFA using interface elements are, for the most part, those with published test data. These structural components were subjected to quasi-static loading in the tests. Thus, the ABAQUS analyses are used to predict geometrically and materially nonlinear equilibrium states. Impact loading, dynamic fracture, reflected stress waves, inertia, and time dependent material behavior are not considered.

Ambur, Damodar R.↗
NASA NTRS2005

Wavy Lineaments on Europa: Fracture Propagation into Combined Nonsynchronous and Diurnal Stress Fields

Understanding the processes that have operated on Europa and the manner in which they may have changed through time is fundamental to understanding the satellite's geology and present-day habitability. Previous studies have shown that lineament patterns on Europa can be explained by accumulation of tensile stress from slow nonsynchronous rotation (NSR), while the cycloidal planforms of other Europan lineaments can be explained if fractures propagate through a diurnally changing tensile stress field. We find that fractures propagated into combined diurnal and NSR stress fields can be "wavy" in planform for NSR stress accumulated over ~2 to 8 of ice shell rotation and average propagation speeds of approx. 1 to 3 m/s. The variety of Europa's observed lineament planforms from cycloidal, to wavy, to arcuate can be produced by accumulation of NSR stress relative to the diurnal stress field. Varying proportions of these stress mechanisms plausibly may be related to a time-variable (slowing) NSR rate.

Crawford, Zane↗
NASA NTRS1999

"Ultra"-Fast Fracture Strength of Advanced Structural Ceramic Materials Studied at Elevated Temperatures

The accurate determination of inert strength is important in reliable life prediction of structural ceramic components. At ambient temperature, the inert strength of a brittle material is typically regarded as free of the effects of slow crack growth due to stress corrosion. Therefore, the inert strength can be determined either by eliminating active species, especially moisture, with an appropriate inert medium, or by using a very high test rate. However, at elevated temperatures, the concept or definition of the inert strength of brittle ceramic materials is not clear, since temperature itself is a degrading environment, resulting in strength degradation through slow crack growth and/or creep. Since the mechanism to control strength is rate-dependent viscous flow, the only conceivable way to determine the inert strength at elevated temperatures is to utilize a very fast test rate that either minimizes the time for or eliminates slow crack growth. Few experimental studies have measured the elevated-temperature, inert (or "ultra"-fast fracture) strength of advanced ceramics. At the NASA Lewis Research Center, an experimental study was initiated to better understand the "ultra"-fast fracture strength behavior of advanced ceramics at elevated temperatures. Fourteen advanced ceramics - one alumina, eleven silicon nitrides, and two silicon carbides - have been tested using constant stress-rate (dynamic fatigue) testing in flexure with a series of stress rates including the "ultra"-fast stress rate of 33 000 MPa/sec with digitally controlled test frames. The results for these 14 advanced ceramics indicate that, notwithstanding possible changes in flaw populations as well as flaw configurations because of elevated temperatures, the strength at 33 000 MPa/sec approached the room-temperature strength or reached a higher value than that determined at the conventional test rate of 30 MPa/sec. On the basis of the experimental data, it can be stated that the elevated-temperature, inert strength of an advanced ceramic material can be defined as the strength where no slow crack growth takes place at the temperature.

Choi, Sung R.↗
NASA NTRS2005

Skin-Stiffener Debond Prediction Based on Computational Fracture Analysis

Interlaminar fracture mechanics has proven useful for characterizing the onset of delaminations in composites and has been used with limited success primarily to investigate onset in fracture toughness specimens and laboratory size coupon type specimens. Future acceptance of the methodology by industry and certification authorities however, requires the successful demonstration of the methodology on structural level. For this purpose a panel was selected that is reinforced with stringers. Shear loading causes the panel to buckle and the resulting out-of-plane deformations initiate skin/stringer separation at the location of an embedded defect. For finite element analysis, the panel and surrounding load fixture were modeled with shell elements. A small section of the stringer foot and the panel in the vicinity of the embedded defect were modeled with a local 3D solid model. Across the width of the stringer foot the mixed-mode strain energy release rates were calculated using the virtual crack closure technique. A failure index was calculated by correlating the results with the mixed-mode failure criterion of the graphite/epoxy material. For small applied loads the failure index is well below one across the entire width. With increasing load the failure index approaches one first near the edge of the stringer foot from which delamination is expected to grow. With increasing delamination lengths the buckling pattern of the panel changes and the failure index increases which suggests that rapid delamination growth from the initial defect is to be expected.

Krueger, Ronald↗
NASA NTRS2006

Effect of Reinforcement Architecture on Fracture of Selectively Reinforced Metallic Compact Tension Specimens

A computer-based parametric study of the effect of reinforcement architectures on fracture response of aluminum compact-tension (CT) specimens is performed. Eleven different reinforcement architectures consisting of rectangular and triangular cross-section reinforcements were evaluated. Reinforced specimens produced between 13 and 28 percent higher fracture load than achieved with the non-reinforced case. Reinforcements with blunt leading edges (rectangular reinforcements) exhibited superior performance relative to the triangular reinforcements with sharp leading edges. Relative to the rectangular reinforcements, the most important architectural feature was reinforcement thickness. At failure, the reinforcements carried between 58 and 85 percent of the load applied to the specimen, suggesting that there is considerable load transfer between the base material and the reinforcement.

Abada, Christopher H.↗
NASA NTRS2006

Multiscale Modeling of Grain-Boundary Fracture: Cohesive Zone Models Parameterized From Atomistic Simulations

A multiscale modeling strategy is developed to study grain boundary fracture in polycrystalline aluminum. Atomistic simulation is used to model fundamental nanoscale deformation and fracture mechanisms and to develop a constitutive relationship for separation along a grain boundary interface. The nanoscale constitutive relationship is then parameterized within a cohesive zone model to represent variations in grain boundary properties. These variations arise from the presence of vacancies, intersticies, and other defects in addition to deviations in grain boundary angle from the baseline configuration considered in the molecular dynamics simulation. The parameterized cohesive zone models are then used to model grain boundaries within finite element analyses of aluminum polycrystals.

Glaessgen, Edward H.↗
NASA NTRS2006

Fracture Response Enhancement Of Aluminum Using In-Situ Selective Reinforcement

A computer-based parametric study of the effect of reinforcement architectures on fracture response of aluminum compact-tension (CT) specimens is performed. Eleven different reinforcement architectures consisting of rectangular and triangular cross-section reinforcements were evaluated. Reinforced specimens produced between 13 and 28 percent higher fracture load than achieved with the unreinforced case. Reinforcements with blunt leading edges (rectangular reinforcements) exhibited superior performance relative to the triangular reinforcements with sharp leading edges. Relative to the rectangular reinforcements, the most important architectural feature was reinforcement thickness. At failure, the reinforcements carried between 58 and 85 percent of the load applied to the specimen, suggesting that there is considerable load transfer between the base material and the reinforcement.

Abada, Christopher H.↗
NASA NTRS2006

Fracture Mechanics Analysis of LH2 Feed Line Flow Liners

Inspections of the Space Shuttle Main Engine revealed fatigue cracks growing from slots in the flow liner of the liquid hydrogen (LH2) feed lines. During flight, the flow liners experience complex loading induced by flow of LH2 and the resonance characteristics of the structure. The flow liners are made of Inconel 718 and had previously not been considered a fracture critical component. However, fatigue failure of a flow liner could have catastrophic effect on the Shuttle engines. A fracture mechanics study was performed to determine if a damage tolerance approach to life management was possible and to determine the sensitivity to the load spectra, material properties, and crack size. The load spectra were derived separately from ground tests and material properties were obtained from coupon tests. The stress-intensity factors for the fatigue cracks were determined from a shell-dynamics approach that simulated the dominant resonant frequencies. Life predictions were obtained using the NASGRO life prediction code. The results indicated that adequate life could not be demonstrated for initial crack lengths of the size that could be detected by traditional NDE techniques.

James, Mark A.↗