Conservatism in the Structural Design Process Associated With Assuming Dynamic Loads are Static 2024
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Undue Conservatisim in Structural Designs
Assuming that dynamic (transient/vibratory) loads are static in the design of structures is a long-standing engineering practice. The assumption is conservative for hardware that will have limited exposure to the specified dynamic environment and fatigue is not a concern. This is the case for most space flight hardware. Once out of the Earth’s atmosphere, significant vibrations are non-existent for most hardware and vibration cycles are limited. Mass is, and has always been, a concern with respect to flight hardware design. How much unnecessary mass due to the subject assumption may be in structural designs was questioned and numerous tests have been performed to qualitatively address that. Tests have been performed on simple aluminum beams, beams with bolted joints and beams with welded joints. Results of those tests are reported in this paper. The objective of these efforts was to demonstrate the order of magnitude of conservatism associated with this engineering process via comparing static to dynamic tests and the longer term endgame is to develop a new or modified quick turnaround structural design process that circumvents assuming dynamic loads are static and results in lighter structural designs. Test results qualitatively demonstrate notable conservatism. Activities to devise the new method are underway.
conservative loads↗
Computational Nanomechanics of Carbon Nanotubes and Composites
Nanomechanics of individual carbon and boron-nitride nanotubes and their application as reinforcing fibers in polymer composites has been reviewed with interplay of theoretical modeling, computer simulations and experimental observations. The emphasis in this work is on elucidating the multi-length scales of the problems involved, and of different simulation techniques that are needed to address specific characteristics of individual nanotubes and nanotube polymer-matrix interfaces. Classical molecular dynamics simulations are shown to be sufficient to describe the generic behavior such as strength and stiffness modulus but are inadequate to describe elastic limit and nature of plastic buckling at large strength. Quantum molecular dynamics simulations are shown to bring out explicit atomic nature dependent behavior of these nanoscale materials objects that are not accessible either via continuum mechanics based descriptions or through classical molecular dynamics based simulations. As examples, we discus local plastic collapse of carbon nanotubes under axial compression and anisotropic plastic buckling of boron-nitride nanotubes. Dependence of the yield strain on the strain rate is addressed through temperature dependent simulations, a transition-state-theory based model of the strain as a function of strain rate and simulation temperature is presented, and in all cases extensive comparisons are made with experimental observations. Mechanical properties of nanotube-polymer composite materials are simulated with diverse nanotube-polymer interface structures (with van der Waals interaction). The atomistic mechanisms of the interface toughening for optimal load transfer through recycling, high-thermal expansion and diffusion coefficient composite formation above glass transition temperature, and enhancement of Young's modulus on addition of nanotubes to polymer are discussed and compared with experimental observations.
Srivastava, Deepak↗
Thermal Fatigue and Fracture Behavior of Ceramic Thermal Barrier Coatings
Thermal fatigue and fracture behavior of plasma-sprayed ceramic thermal barrier coatings has been investigated under high heat flux and thermal cyclic conditions. The coating crack propagation is studied under laser heat flux cyclic thermal loading, and is correlated with dynamic fatigue and strength test results. The coating stress response and inelasticity, fatigue and creep interactions, and interface damage mechanisms during dynamic thermal fatigue processes are emphasized.
Zhu, Dong-Ming↗
Dynamic Breaking Tests of Airplane Parts
The static stresses of airplane parts, the magnitude of which can be determined with the aid of static load assumptions, are mostly superposed by dynamic stresses, the magnitude of which has been but little explored. The object of the present investigation is to show how the strength of airplane parts can best be tested with respect to dynamic stresses with and without superposed static loading, and to what extent the dynamic strength of the parts depends on their structural design. Experimental apparatus and evaluation methods were developed and tried for the execution of vibration-strength tests with entire structural parts both with and without superposed static loading. Altogether ten metal spars and spar pieces and two wooden spars were subjected to vibration breaking tests.
Hertel, Heinrich↗
Simulating the Effects of Carbon Nanotube Continuity and Interfacial Bonding on Composite Strength and Stiffness
Molecular dynamics simulations of carbon nanotube (CNT) composites, in which the CNTs are continuous across the periodic boundary, overestimate the experimentally measured mechanical properties of CNT composites along the fiber direction. Since the CNTs in these composites are much shorter than the composite dimensions, load must be transferred either directly between CNTs or through the matrix, a mechanism that is absent in simulations of effectively continuous CNTs. In this study, the elastic and fracture properties of high volume fraction discontinuous carbon nanotube/amorphous carbon composite systems were compared to those of otherwise equivalent continuous CNT composites using ReaxFF reactive molecular dynamics simulations. These simulations were used to show how the number of nanotube-matrix interfacial covalent bonds affect composite mechanical properties. Furthermore, the mechanical impact of interfacial bonding was decomposed to reveal its effect on the properties of the CNTs, the interfacial layer of matrix, and the bulk matrix. For the composites with continuous reinforcement, it was found that any degree of interfacial bonding has a negative impact on axial tensile strength and stiffness. This is due to disruption of the structure of the CNTs and interfacial matrix layer by the interfacial bonds. For the discontinuous composites, the modulus was maximized between 4%-7% interfacial bonding and the strength continues to increase up to the highest levels of interfacial bonding studied. Areas of low stress and voids were observed in the simulated discontinuous composites at the ends of the tubes, from which fracture was observed to initiate. Experimental carbon nanotube yarn composites were fabricated and tested. The results were used to illustrate knockdown factors relative to the mechanical performance of the tubes themselves.
Benjamin D Jensen↗
Elevated temperature mechanical behavior of monolithic and SiC whisker-reinforced silicon nitrides
The mechanical behavior of a 30 volume percent SiC whisker reinforced silicon nitride and a similar monolithic silicon nitride were measured at several temperatures. Measurements included strength, fracture toughness, crack growth resistance, dynamic fatigue susceptibility, post oxidation strength, and creep rate. Strength controlling defects were determined with fractographic analysis. The addition of SiC whiskers to silicon nitride did not substantially improve the strength, fracture toughness, or crack growth resistance. However, the fatigue resistance, post oxidation strength, and creep resistance were diminished by the whisker addition.
Salem, Jonathan A.↗
Molecular Modeling of the Poling of Piezoelectric Polyimides
The computational method described in this paper allows the calculation of the dielectric relaxation strength of an amorphous polymer based solely upon its chemical structure. The 4,4' oxydiphthalic anhydride (ODPA) dianhydride and bis-aminophenoxybenzene (APB) diamine based polyimides, (beta-CN) APB-ODPA and APB-ODPA were studied. Amorphous cells were constructed and then poled using molecular dynamics. Dielectric relaxation strengths of Delta(epsilon) = 17.8 for (beta-CN) APB-ODPA and Delta(epsilon) = 7.7 for APB-ODPA were predicted. These values are in excellent agreement with the experimental values. It was found that both the pendant nitrile dipole and the backbone anhydride residue dipole make significant contributions to the polyimides dielectric response. Specifically, it was shown that the difference in the magnitude of the dielectric relaxations is directly attributable to the nitrile dipole. The size of the relaxations indicate an absence of cooperative dipolar motions, The model was used to explain these results in terms of the average orientation of the nitrile and anhydride dipoles to within 51 deg. and 63 deg., respectively, of the applied electric field.
Young, J. A.↗
Gear optimization
The use of formal numerical optimization methods for the design of gears is investigated. To achieve this, computer codes were developed for the analysis of spur gears and spiral bevel gears. These codes calculate the life, dynamic load, bending strength, surface durability, gear weight and size, and various geometric parameters. It is necessary to calculate all such important responses because they all represent competing requirements in the design process. The codes developed here were written in subroutine form and coupled to the COPES/ADS general purpose optimization program. This code allows the user to define the optimization problem at the time of program execution. Typical design variables include face width, number of teeth and diametral pitch. The user is free to choose any calculated response as the design objective to minimize or maximize and may impose lower and upper bounds on any calculated responses. Typical examples include life maximization with limits on dynamic load, stress, weight, etc. or minimization of weight subject to limits on life, dynamic load, etc. The research codes were written in modular form for easy expansion and so that they could be combined to create a multiple reduction optimization capability in future.
Vanderplaats, G. N.↗
Fatigue of boron-aluminum composites bonds and joints
Study examines effects of boron filament diameter on bonds and joints in boron-aluminum composite. Data include static strength, fatigue, and dynamic moduli of elasticity. Manson-Coffin analyses and metallurgical and fracture surface evaluation were also performed.
Hersh, M. S.↗
The effect of large-scale eddies on climatic change.
A parameterization for the fluxes of sensible heat by large-scale eddies developed in an earlier paper is incorporated into a model for the mean temperature structure of an atmosphere including only these fluxes and the radiative fluxes. The climatic changes in this simple model are then studied in order to assess the strength of the dynamical feedback and to gain insight into how dynamical parameters may change in more sophisticated climatic models. The model shows the following qualitative changes: (1) an increase in the solar constant leads to increased static stability, decreased dynamic stability, and stronger horizontal and vertical winds; (2) an increase in the amount of atmospheric absorption leads to decreased static and dynamic stability, and stronger horizontal and vertical winds; and (3) an increase in rotation rate leads to greater static and dynamic stability, weaker horizontal winds, and stronger vertical winds.
Stone, P. H.↗
Atmosphere of Venus: Implications of Venera 8 sunlight measurements
Venera 8 measurements of solar illumination within the atmosphere of Venus are quantitatively analyzed by using a multilayer model atmosphere. The analysis shows that there are at least three different scattering layers in the atmosphere of Venus and the total cloud optical thickness is about 10 or greater. However, because of the nature of the observations, it is not possible to determine the vertical distribution of absorbed solar energy, which would reveal the drive for the atmospheric dynamics and the strength of the greenhouse effect. Future spacecraft observations should be designed to (1) measure both upward and downward solar fluxes, (2) include measurements of the highest cloud layers, and (3) employ narrow-band and broad-band sensors.-
Lacis, A. A.↗
Concepts and techniques for ultrasonic evaluation of material mechanical properties
Ultrasonic methods that can be used for material strength are reviewed. Emergency technology involving advanced ultrasonic techniques and associated measurements is described. It is shown that ultrasonic NDE is particularly useful in this area because it involves mechanical elastic waves that are strongly modulated by morphological factors that govern mechanical strength and also dynamic failure modes. These aspects of ultrasonic NDE are described in conjunction with advanced approaches and theoretical concepts for signal acquisition and analysis for materials characterization. It is emphasized that the technology is in its infancy and that much effort is still required before the techniques and concepts can be transferred from laboratory to field conditions.
Vary, A.↗
Studies of new perfluoroether elastomeric sealants
Channel and filleting sealants were developed successfully from cyano and diamidoxime terminated perfluoro alkylene ether prepolymers. The prepolymers were polymerized, formulated and tested. The polymers and/or formulations therefrom were evaluated as to their physical, mechanical and chemical properties (i.e., specific gravity, hardness, nonvolatile content, corrosion resistance, stress corrosion, pressure rupture resistance, low temperature flexibility, gap sealing efficiency, tensile strength and elongation, dynamic mechanical behavior, compression set, fuel resistance, thermal properties and processability). Other applications of the formulated polymrs and incorporation of the basic prepolymers into other polymeric systems were investigated. A cyano terminated perfluoro alkylene oxide triazine was formulated and partially evaluated. The channel sealant in its present formulation has excellent pressure rupture resistance and surpasses present MIL specifications before and after fuel and heat aging.
Basiulis, D. I.↗
Carbon Nanotube Based Molecular Electronics and Motors: A View from Classical and Quantum Dynamics Simulations
The tubular forms of fullerenes popularly known as carbon nanotubes are experimentally produced as single-, multiwall, and rope configurations. The nanotubes and nanoropes have shown to exhibit unusual mechanical and electronic properties. The single wall nanotubes exhibit both semiconducting and metallic behavior. In short undefected lengths they are the known strongest fibers which are unbreakable even when bent in half. Grown in ropes their tensile strength is approximately 100 times greater than steel at only one sixth the weight. Employing large scale classical and quantum molecular dynamics simulations we will explore the use of carbon nanotubes and carbon nanotube junctions in 2-, 3-, and 4-point molecular electronic device components, dynamic strength characterization for compressive, bending and torsional strains, and chemical functionalization for possible use in a nanoscale molecular motor. The above is an unclassified material produced for non-competitive basic research in the nanotechnology area.
Srivastava, Deepak↗
Thin tailored composite wing for civil tiltrotor
The tiltrotor aircraft is a flight vehicle which combines the efficient low speed (i.e., take-off, landing, and hover) characteristics of a helicopter with the efficient cruise speed of a turboprop airplane. A well-known example of such vehicle is the Bell-Boeing V-22 Osprey. The high cruise speed and range constraints placed on the civil tiltrotor require a relatively thin wing to increase the drag-divergence Mach number which translates into lower compressibility drag. It is required to reduce the wing maximum thickness-to-chord ratio t/c from 23% (i.e., V-22 wing) to 18%. While a reduction in wing thickness results in improved aerodynamic efficiency, it has an adverse effect on the wing structure and it tends to reduce structural stiffness. If ignored, the reduction in wing stiffness leads to susceptibility to aeroelastic and dynamic instabilities which may consequently cause a catastrophic failure. By taking advantage of the directional stiffness characteristics of composite materials the wing structure may be tailored to have the necessary stiffness, at a lower thickness, while keeping the weight low. The goal of this study is to design a wing structure for minimum weight subject to structural, dynamic and aeroelastic constraints. The structural constraints are in terms of strength and buckling allowables. The dynamic constraints are in terms of wing natural frequencies in vertical and horizontal bending and torsion. The aeroelastic constraints are in terms of frequency placement of the wing structure relative to those of the rotor system. The wing-rotor-pylon aeroelastic and dynamic interactions are limited in this design study by holding the cruise speed, rotor-pylon system, and wing geometric attributes fixed. To assure that the wing-rotor stability margins are maintained a more rigorous analysis based on a detailed model of the rotor system will need to ensue following the design study. The skin-stringer-rib type architecture is used for the wing-box structure. The design variables include upper and lower skin ply thicknesses and orientation angles, spar and rib web thicknesses and cap areas, and stringer cross-sectional areas. These design variables will allow the maximum tailoring of the structure to meet the design requirements most efficiently. Initial dynamic analysis has been conducted using MSC/NASTRAN to determine the baseline wing's frequencies and mode shapes. For the design study we intend to use the finite-element based code called WIDOWAC (Wing Design Optimization With Aeroeastic Constraints) that was developed at NASA Langley in early 1970's for airplane wing structural analysis and preliminary design. Currently, the focus is on modification and validation of this code which will be used for the civil tiltrotor design efforts.
Rais-Rohani, Masoud↗
Impact Cratering Calculations
Many Martian craters are surrounded by ejecta blankets which appear to have been fluidized forming lobate and layered deposits terminated by one or more continuous distal scarps, or ramparts. One of the first hypotheses for the formation of so-called rampart ejecta features was shock-melting of subsurface ice, entrainment of liquid water into the ejecta blanket, and subsequent fluidized flow. Our work quantifies this concept. Rampart ejecta found on all but the youngest volcanic and polar regions, and the different rampart ejecta morphologies are correlated with crater size and terrain. In addition, the minimum diameter of craters with rampart features decreases with increasing latitude indicating that ice laden crust resides closer to the surface as one goes poleward on Mars. Our second goal in was to determine what strength model(s) reproduce the faults and complex features found in large scale gravity driven craters. Collapse features found in large scale craters require that the rock strength weaken as a result of the shock processing of rock and the later cratering shear flows. In addition to the presence of molten silicate in the intensely shocked region, the presence of water, either ambient, or the result of shock melting of ice weakens rock. There are several other mechanisms for the reduction of strength in geologic materials including dynamic tensile and shear induced fracturing. Fracturing is a mechanism for large reductions in strength. We found that by incorporating damage into the models that we could in a single integrated impact calculation, starting in the atmosphere produce final crater profiles having the major features found in the field measurements (central uplifts, inner ring, terracing and faulting). This was accomplished with undamaged surface strengths (0.1 GPa) and in depth strengths (1.0 GPa).
Ahrens, Thomas J.↗
Analytical model of foreshock ion interaction with a discontinuity: A statistical study
When a solar wind discontinuity interacts with foreshock ions, foreshock transients such as hot flow anomalies and foreshock bubbles can form. These create significant dynamic pressure perturbations disturbing the bow shock, magnetopause, and magnetosphere-ionosphere system. However, presently these phenomena are not predictable. In the accompanying paper, we derived analytical equations of foreshock ion partial gyration around a discontinuity and the resultant current density. In this study, we utilize the derived current density strength to model the energy conversion from the foreshock ions, which drives the outward motion or expansion of the solar wind plasma away from the discontinuity. We show that the model expansion speeds match those from local hybrid simulations for varying foreshock ion parameters. Using MMS, we conduct a statistical study showing that the model expansion speeds are moderately correlated with the magnetic field strength variations and the dynamic pressure decreases around discontinuities with correlation coefficients larger than 0.5. We use conjunctions between ARTEMIS and MMS to show that the model expansion speeds are typically large for those already-formed foreshock transients. Our results show that our model can be reasonably successful in predicting significant dynamic pressure disturbances caused by foreshock ion-discontinuity interactions. We discuss ways to improve the model in the future.
Terry Z. Liu↗