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At least 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Interim Development of new Class B Code Case with Variable Design Lifetime and enhanced design rules to guard against cyclic structural failure mode

This report summarizes updates on the ongoing development of the new American Society of Mechanical Engineers Section III, Division 5, Class B rules to address the potential failure modes of Class B components. An initial design-by-analysis approach and supporting design rules are presented. The elastic-perfectly plastic (EPP) analysis approach has been adopted for primary stress limit and ratcheting check to prevent the component failure against the structural failure mode against primary load and strain accumulation due to cyclic loads. The creep-fatigue damage assessment uses explicitly defined elastic follow-up calculated from the stress concentration region of given component. Damage fraction calculation uses a novel coupled approach to capture the influence of the elastic follow-up and provide adequate conservatism for Class B components. The proposed Class B rules does not use the stress classification approach and uses the combined loads to assess component.

36 MATERIALS SCIENCE↗
NASA NTRS2009

Residual Stresses and Critical Initial Flaw Size Analyses of Welds

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). A series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on the fatigue life. The purpose of the weld analyses was to model the weld process using a variety of sequences to determine the 'best' sequence in terms of weld residual stresses and distortions. The many factors examined in this study include weld design (single-V, double-V groove), weld sequence, boundary conditions, and material properties, among others. The results of this weld analysis are included with service loads to perform a fatigue and critical initial flaw size evaluation.

Brust, Frederick W.↗
DOE OSTI2024

TEAMER Technical Support for Aquantis (Materials) (Final Report)

The Aquantis Tidal Power Tug is a unique synthesis of best-available technologies and materials configured as a novel spar vessel to create an optimal platform for tidal stream energy conversion. The Power Tug utilizes an upstream-facing horizontal, 2-bladed rotor. To drive down capital costs and extend life, Aquantis proposes to employ new materials for the blades that are both less expensive than current state-of-the-art materials and are potentially better suited for survival in a submerged, seawater environment. Coupons from a novel geopolymer material will be tested in a load frame to characterize material properties. The Requestor is requesting technical assistance for evaluating mechanical properties of a novel geopolymer material for application in tidal stream energy conversion systems. This work will establish characteristic properties of a geopolymer material under dry and saturated conditions through material coupon testing. Material coupons will be tested to characterize properties including: a) Tensile strength, b) Compression strength, c) Flexural strength, d) Modulus of elasticity, e) Fatigue strength at varying load levels. The types of material tests performed will be guided by characteristics required to validate material properties for use in full-scale structures. Characterization of material properties that consider the demands of a full-scale structure is a necessary step in research and development that can enable the use of geopolymer materials in tidal stream energy conversion systems.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Effects of wind field characteristics on pitch bearing reliability: a case study of 5 MW reference wind turbine at onshore and offshore sites; Auswirkungen von Windfeldeigenschaften auf die Zuverlässigkeit von Rotorblattlagern: eine Fallstudie über eine 5-MW-Referenz-Windkraftanlage an Onshore- und Offshore-Standorten

This paper presents a study on pitch bearing basic rating life affected by wind field characteristics at both onshore and offshore wind sites. The National Renewable Energy Laboratory 5 MW reference wind turbine is selected for the study. Wind field characteristics including reference hub height mean wind speed, wind speed distribution, wind shear, and vertical inflow are studied. A decoupled approach is employed where global analysis is performed first. Second, the load effects from the global analysis are applied on a reference pitch bearing designed based on best industrial practices. For the case study onshore site, it is found that the Kernel density estimation best fits the wind distribution, while the International Electrotechnical Commission proposed distribution appears to be not suitable. Moreover, it is shown that the seed number has high effect on the bearing life in turbulence wind and the wind speeds around rated have the highest contribution in both bearing fatigue damage and extreme load failure. The results contribute to better understanding of the wind field characteristics on the pitch bearing life.

17 WIND ENERGY↗
NASA NTRS1991

Computational simulation of acoustic fatigue for hot composite structures

This paper presents predictive methods/codes for computational simulation of acoustic fatigue resistance of hot composite structures subjected to acoustic excitation emanating from an adjacent vibrating component. Select codes developed over the past two decades at the NASA Lewis Research Center are used. The codes include computation of (1) acoustic noise generated from a vibrating component, (2) degradation in material properties of the composite laminate at use temperature, (3) dynamic response of acoustically excited hot multilayered composite structure, (4) degradation in the first-ply strength of the excited structure due to acoustic loading, and (5) acoustic fatigue resistance of the excited structure, including 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 moisure) is to relieve the residual stresses leading to an increase in the acoustic fatigue life of the excited panel.

Singhal, S. N.↗
NASA NTRS1980

Fatigue properties of shuttle thermal protection system

Static and cyclic load tests were conducted to determine the static and fatigue strength of the RIS tile/SIP thermal protection system used on the orbiter of the space shuttle. The material systems investigated include the densified and undensified LI-900 tile system on the .40 cm thick SIP and the densified and undensified LI-2200 tile system on the .23 cm (.090 inch) thick SIP. The tests were conducted at room temperature with a fully reversed uniform cyclic loading at 1 Hertz. Cyclic loading causes a relatively large reduction in the stress level that each of the SIP/tile systems can withstand for a small number of cycles. For example, the average static strength of the .40 cm thick SIP/LI-900 tile system is reduced from 86 kPa to 62 kPa for a thousand cycles. Although the .23 cm thick SIP/LI-2200 tile system has a higher static strength, similar reductions in the fatigue strength are noted. Densifying the faying surface of the RSI tile changes the failure mode from the SIP/tile interface to the parent RSI or the SIP and thus greatly increases the static strength of the system. Fatigue failure for the densified tile system, however, occurs due to complete separation or excessive elongation of the SIP and the fatigue strength is only slightly greater than that for the undensified tile system.

Sawyer, J. W.↗
NASA NTRS2015

Effect of Buckling Modes on the Fatigue Life and Damage Tolerance of Stiffened Structures

The postbuckling response and the collapse of composite specimens with a co-cured hat stringer are investigated experimentally and numerically. These specimens are designed to evaluate the postbuckling response and the effect of an embedded defect on the collapse load and the mode of failure. Tests performed using controlled conditions and detailed instrumentation demonstrate that the damage tolerance, fatigue life, and collapse loads are closely tied with the mode of the postbuckling deformation, which can be different between two nominally identical specimens. Modes that tend to open skin/stringer defects are the most damaging to the structure. However, skin/stringer bond defects can also propagate under shearing modes. In the proposed paper, the effects of initial shape imperfections on the postbuckling modes and the interaction between different postbuckling deformations and the propagation of skin/stringer bond defects under quasi-static or fatigue loads will be examined.

Davila, Carlos G.↗
NASA NTRS1980

Evaluation of the cyclic behavior of aircraft turbine disk alloys, part 2

Several nickel-base aircraft turbine disk superalloys were evaluated at 650 C for resistance to fatigue crack initiation and propagation under cyclic and cyclic/dwell conditions. Controlled strain low cycle fatigue (LCF) and controlled load crack propagation tests were performed and results utilized to provide a direct comparison among the alloys. Tests were performed on selected alloys to evaluate the effects of hold times, mean stresses, stress-dwell cycle types, inert environment, and contractor test methods. At the lower total strain ranges of interest, the alloys exhibited generally increasing initiation life with increasing tensile strength for both cyclic (0.33 Hz) and cyclic/dwell (900-sec hold per cycle) conditions. Rank order of the alloys by LCF initiation life changed substantially at higher strain ranges, approaching the rank order expected from monotonic tensile ductilities. The effect of the 900 sec (15 min) hold time fatigue life varied significantly from alloy to alloy. Generally, the higher-strength, finer-grained alloys exhibited more significant reductions in fatigue life due to the dwell. The effects of mean strain were found to be negligible and the effects of mean stress were pronounced. At high strain ranges the mean stress was near zero and did not contribute to reduction in life. At low strain ranges, however, mean stresses were large and significant reductions in LCF lives occurred.

Cowles, B. A.↗
NASA NTRS1995

A record of all marker bands found in the upper rivet rows of 2 adjacent bays from a fuselage lap splice joint

A full scale fuselage test article was subjected to 60,000 load cycles (pressurizations) to study the effect of widespread fatigue damage in fuselage structures. Every 10,000 cycles coded marker block loading sequences were used to mark the fracture surfaces of the fatigue cracks propagating within the panel. The loading sequences consisted of series of underloads combined with a series of full pressurizations. The combination of loads and underloads marked the fracture surfaces with marker bands that could later be used to reconstruct the fatigue crack growth history of selected regions within the test article. Thirty rivet holes comprising the upper rivet rows from two adjacent bays (bays #3 and #4) from a fuselage lap splice joint were examined for the purpose of this study. Optical and scanning electron microscopy (SEM) were used to locate the marker bands.

Willard, Scott A.↗
NASA NTRS1990

Fatigue crack propagation in aerospace aluminum alloys

This paper reviews fracture mechanics based, damage tolerant characterizations and predictions of fatigue crack growth in aerospace aluminum alloys. The results of laboratory experimentation and modeling are summarized in the areas of: (1) fatigue crack closure, (2) the wide range crack growth rate response of conventional aluminum alloys, (3) the fatigue behavior of advanced monolithic aluminum alloys and metal matrix composites, (4) the short crack problem, (5) environmental fatigue, and (6) variable amplitude loading. Remaining uncertainties and necessary research are identified. This work provides a foundation for the development of fatigue resistant alloys and composites, next generation life prediction codes for new structural designs and extreme environments, and to counter the problem of aging components.

Gangloff, R. P.↗
NASA NTRS2000

Dynamic Stall Characteristics of Drooped Leading Edge Airfoils

Helicopters in high-speed forward flight usually experience large regions of dynamic stall over the retreating side of the rotor disk. The rapid variations in the lift and pitching moments associated with the stall process can result in vibratory loads, and can cause fatigue and failure of pitch links. In some instances, the large time lag between the aerodynamic forces and the blade motion can trigger stall flutter. A number of techniques for the alleviation of dynamic stall have been proposed and studied by researchers. Passive and active control techniques have both been explored. Passive techniques include the use of high solidity rotors that reduce the lift coefficients of individual blades, leading edge slots and leading edge slats. Active control techniques include steady and unsteady blowing, and dynamically deformable leading edge (DDLE) airfoils. Considerable amount of experimental and numerical data has been collected on the effectiveness of these concepts. One concept that has not received as much attention is the drooped-leading edge airfoil idea. It has been observed in wind tunnel studies and flight tests that drooped leading edge airfoils can have a milder dynamic stall, with a significantly milder load hysteresis. Drooped leading edge airfoils may not, however, be suitable at other conditions, e.g. in hover, or in transonic flow. Work needs to be done on the analysis and design of drooped leading edge airfoils for efficient operation in a variety of flight regimes (hover, dynamic stall, and transonic flow). One concept that is worthy of investigation is the dynamically drooping airfoil, where the leading edge shape is changed roughly once-per-rev to mitigate the dynamic stall.

Sankar, Lakshmi N.↗
NASA NTRS1991

Development of methodology for qualifying safety critical A286 threaded fasteners

A test program was initiated at the Jet Propulsion Laboratory to experimentally determine the cyclic fatigue life of pre-cracked A286 stainless steel fasteners which just survived a proof test to a prescribed fraction of their ultimate tensile strength. The functional dependency of the cyclic fatigue life of a fastener on the fatigue stress (mean and alternating stresses), fastener size, material tensile strength, and proof load was formulated using the NASA/FLAGRO computer program. It was found that proof load has the strongest effect on fatigue life, while the mean stress has the least effect. The fastener size only has a minor effect, but the alternating stress range has a strong influence on the fatigue life of fasteners. Limited experimental verification of the hypothesized functional relationship is provided in this program for the effect of proof load and fastener size in addition to the analytic verification.

Hsieh, Cheng↗
NASA NTRS1990

High temperature tension-compression fatigue behavior of a tungsten copper composite

The high temperature fatigue of a (O)12 tungsten fiber reinforced copper matrix composite was investigated. Specimens having fiber volume percentages of 10 and 36 were fatigued under fully-reversed, strain-controlled conditions at both 260 and 560 C. The fatigue life was found to be independent of fiber volume fraction because fatigue damage preferentially occurred in the matrix. Also, the composite fatigue lives were shorter at 560 C as compared to 260 C due to changes in mode of matrix failure. On a total strain basis, the fatigue life of the composite at 560 C was the same as the life of unreinforced copper, indicating that the presence of the fibers did not degrade the fatigue resistance of the copper matrix in this composite system. Comparison of strain-controlled fatigue data to previously-generated load-controlled data revealed that the strain-controlled fatigue lives were longer because of mean strain and mean stress effects.

Verrilli, Michael J.↗
NASA NTRS1997

Prediction of Crack Growth under Variable-Amplitude Loading in Thin-Sheet 2024-T3 Aluminum Alloys

The present paper is concerned with the application of a "plasticity-induced" crack closure model to study fatigue crack growth under various load histories. The model was based on the Dugdale model but modified to leave plastically deformed material in the wake of the advancing crack. The model was used to correlate crack growth rates under constant-amplitude loading and then used to predict crack growth under variable-amplitude and spectrum loading on thin-sheet 2024- T3 aluminum alloys. Predicted crack-opening stresses agreed well with test data from the literature. The crack-growth lives agreed within a factor of two for single and repeated spike overloads/underloads and within 20 percent for spectrum loading. Differences were attributed to fretting-product-debris-induced closure and three-dimensional affects not included in the model.

Newman, J. C., Jr.↗
NASA NTRS1998

Small Crack Growth and Fatigue Life Predictions for High-Strength Aluminium Alloys: Experimental and Fracture Mechanics Analysis - Part 1

The small crack effect was investigated in two high-strength aluminium alloys: 7075-T6 bare and LC9cs clad alloy. Both experimental and analytical investigations were conducted to study crack initiation and growth of small cracks. In the experimental program, fatigue tests, small crack and large crack tests A,ere conducted under constant amplitude and Mini-TWIST spectrum loading conditions. A pronounced small crack effect was observed in both materials, especially for the negative stress ratios. For all loading conditions, most of the fatigue life of the SENT specimens was shown to be crack propagation from initial material defects or from the cladding layer. In the analysis program, three-dimensional finite element and A weight function methods were used to determine stress intensity factors and to develop SIF equations for surface and corner cracks at the notch in the SENT specimens. A plastisity-induced crack-closure model was used to correlate small and large crack data, and to make fatigue life predictions, Predicted crack-growth rates and fatigue lives agreed well with experiments. A total fatigue life prediction method for the aluminum alloys was developed and demonstrated using the crack-closure model.

Wu, X. R.↗
DOE OSTI2025

DROP DURABILITY ASSESSMENT OF ELECTRONIC ASSEMBLIES UNDER OFF-AXIS LOADING WITH SKEWED FIXTURES

This thesis studies drop durability of electronic assemblies when the acceleration vector is oriented at 45° to the out-of-plane direction of the circuit card. The off-axis drop tests are accomplished with a skewed fixture and are conducted as a proxy for multiaxial drop testing. Advanced shock testing and vibration test methods have been developed over the last few decades to better represent real-world field environments during ground-based laboratory testing. However, many of these test methods require expensive and specialized equipment not available in most laboratories. An alternative approach for approximating simultaneous loading along multiple axes on conventional equipment utilizes skewed fixtures which have seen use in off-axis random vibration and drop impact testing. These methods generally rely on the conversion of a uniaxial input load from the test equipment (using a uniaxial drop tower or shaker) into a multiaxial load when resolved in the reference frame of the test article (mounted on a skewed fixture). Skewed fixture design is presented and recommendations for conducting skewed angle drop testing are introduced based on local measurements along the skewed face of the fixture to accurately monitor the impact event. Characterization tests were performed with a skewed fixture, at simultaneous acceleration loads from 500 to 3,000 g in two (in-plane and out-of-plane) directions, while meeting standard time domain tolerances. Upon experimental characterization, drop shock durability tests were conducted on a printed circuit assembly (PCA). Mean drops-to-failure were measured and quantified with Weibull statistics. Dominant solder joint failure modes were identified via failure analysis. Prior work on inclined angle impact testing is limited, and the majority of solder joint interconnect level fatigue studies are conducted considering perpendicular loading normal the circuit card. Low-cycle fatigue curves are generated based on plastic strain and plastic work density within the solder joint. A multiscale nonlinear finite element model is used to relate board-level flexure to solder joint interconnect level plastic strain. A high strain rate solder constitutive model allows for accurate modeling of solder plasticity resulting from high-impact drop shock. Fatigue parameters are computed from the Coffin-Manson relation and Palmgren-Miner damage accumulation. This work serves to apply established low-cycle fatigue methods for conventional drop shock loading (impact normal to circuit card) to non-perpendicular loading with a skewed fixture.

Hower, Jonathan [Kansas City National Security Cam↗
DOE OSTI2022

Control of High-Temperature Static and Transient Thermomechanical Behavior of SiMo Ductile Iron by Al Alloying

Abstract Silicon and molybdenum ( SiMo ) ductile iron is commonly used for exhaust manifolds because these components experience thermal cycling in oxidizing environment, which requires resistance to fatigue during transient thermomechanical loads. Previous studies have demonstrated that alloying elements, such as Al , to SiMo ductile iron reduces the amount of surface degradation during static high-temperature exposure. However, deterioration of sphericity of the graphite nodules and a decrease in ductility could affect the tendency of cracking during thermal cycling. In this article, the effect of Al alloying on static and transient thermomechanical behavior of SiMo ductile iron was investigated to optimize the amount of Al alloying. A thermodynamic approach was used to confirm the effect of the Al alloying on the phase transformations in two SiMo cast irons, alloyed by 1.8% Al and 3% Al . These two alloys were cast in a laboratory along with the baseline SiMo ductile iron. Several experimental methods were used to evaluate the dimensional stability, physical properties, static oxidation, and failure resistance during constrained thermal cycling testing to compare their high-temperature capability. Experimental results verified that Al alloying increases the temperature range and decreases volume change during eutectoid transformation, which together with enhancement of oxidation protection improved the dimensional stability. Thermocycling tests showed that the number of cycles to failure depends on the amount of Al alloying and the applied high-temperature exposure during each cycle. SEM/EDX, high-resolution TEM and µCT analysis were used to verify the mechanism resulting from the Al alloying protection. It was shown that an optimal level of Al alloying for balancing oxidation and thermal cracking resistance depends on thermomechanical conditions of application.

36 MATERIALS SCIENCE↗
DOE OSTI2022

RADAMS: Resilient and adaptive alert and attention management strategy against Informational Denial-of-Service (IDoS) attacks

Attacks exploiting human attentional vulnerability have posed severe threats to cybersecurity. In this work, we identify and formally define a new type of proactive attentional attacks called Informational Denial-of-Service (IDoS) attacks that generate a large volume of feint attacks to overload human operators and hide real attacks among feints. Here, we incorporate human factors (e.g., levels of expertise, stress, and efficiency) and empirical psychological results (e.g., the Yerkes-Dodson law and the sunk cost fallacy) to model the operators’ attention dynamics and their decision-making processes along with the real-time alert monitoring and inspection. To assist human operators in dismissing the feints and escalating the real attacks timely and accurately, we develop a Resilient and Adaptive Data-driven alert and Attention Management Strategy (RADAMS) that de-emphasizes alerts selectively based on the abstracted category labels of the alerts. RADAMS uses reinforcement learning to achieve a customized and transferable design for various human operators and evolving IDoS attacks. The integrated modeling and theoretical analysis lead to the Product Principle of Attention (PPoA), fundamental limits, and the tradeoff among crucial human and economic factors. Experimental results corroborate that the proposed strategy outperforms the default strategy and can reduce the IDoS risk by as much as 20%. Besides, the strategy is resilient to large variations of costs, attack frequencies, and human attention capacities. We have recognized interesting phenomena such as attentional risk equivalency, attacker’s dilemma, and the half-truth optimal attack strategy.

97 MATHEMATICS AND COMPUTING↗