SEARCH · Engineering Papers

Results for “high cycle fatigue”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

NASA NTRS1988

Extending Fatigue Lives Of Selected Alloys

Rejuvenating treatments demonstrated. Experiments with three alloys show some combinations of heat treatment, hot isostatic pressing, and/or surface treatment extends cycle lives of fatigue-damaged or fatigue-precracked specimens. For each alloy, tests were first done to determine "baseline" high-cycle-fatigue lives and high-cycle-fatigue failure modes over range of test conditions. Controlled fatigue damage introduced into specimens. Damaged specimens subjected to candidate rejuvenating treatments, then tested to failure. Effectiveness of each treatment judged by comparing fatigue data of damaged and treated specimens to "baseline" fatigue and data taken at same test conditions.

Matejczyk, D. E.↗

NASA NTRS1977

Types of rotor failure and characteristics of fragments

Noncontained rotor failures in U.K. engines resulting from low cycle fatigue, low cycle fatigue with superimposed high cycle fatigue, and overheating and-or overspeeding were analyzed. The size, shape, weight, velocity, energy, and direction of the fragments released from turbines and compressors were studied and are presented in graph.

Mccarthy, D.↗

NASA NTRS1983

Relation of cyclic loading pattern to microstructural fracture in creep fatigue

Creep-fatigue-environment interaction is discussed using the 'strainrange partitioning' (SRP) framework as a basis. The four generic SRP strainrange types are studied with a view of revealing differences in micromechanisms of deformation and fatigue degradation. Each combines in a different manner the degradation associated with slip-plane sliding, grain-boundary sliding, migration, cavitation, void development and environmental interaction; hence the approch is useful in delineating the relative importance of these mechanisms in the different loadings. Micromechanistic results are shown for a number of materials, including 316 SS, wrought heat resistant alloys, several nickel-base superalloys, and a tantalum base alloy, T-111. Although there is a commonality of basic behavior, the differences are useful in delineation several important principles of interpretation. Some quantitative results are presented for 316 SS, involving crack initiation and early crack growth, as well as the interaction of low-cycle fatigue with high-cycle fatigue.

Manson, S. S.↗

DOE OSTI2021

Small-sized specimen design with the provision for high-frequency bending-fatigue testing

The testing and study of emerging materials—such as additively manufactured materials—demands for specimen designs that are cost effective and time saving. Here the design of a small-sized bending-fatigue test specimen for an ultrasonic fatigue testing system is reported in this paper. The design is optimized based on the finite element analysis and analytical-solution results to achieve the proper vibration shape and stress distribution. The proposed design is evaluated in the high- and very-high-cycle fatigue regimes under 20-kHz frequency. Both simulation and testing results confirm that the desirable vibration mode occurs and the specimen fails at the designated test (gauge) section, where the maximum stress exists. The stress–life (S–N) curve is obtained for Inconel alloy 718 and indicates an expected trend.

36 MATERIALS SCIENCE↗

NASA NTRS2013

Understanding How Kurtosis Is Transferred from Input Acceleration to Stress Response and Its Influence on Fatigue Llife

High cycle fatigue of metals typically occurs through long term exposure to time varying loads which, although modest in amplitude, give rise to microscopic cracks that can ultimately propagate to failure. The fatigue life of a component is primarily dependent on the stress amplitude response at critical failure locations. For most vibration tests, it is common to assume a Gaussian distribution of both the input acceleration and stress response. In real life, however, it is common to experience non-Gaussian acceleration input, and this can cause the response to be non-Gaussian. Examples of non-Gaussian loads include road irregularities such as potholes in the automotive world or turbulent boundary layer pressure fluctuations for the aerospace sector or more generally wind, wave or high amplitude acoustic loads. The paper first reviews some of the methods used to generate non-Gaussian excitation signals with a given power spectral density and kurtosis. The kurtosis of the response is examined once the signal is passed through a linear time invariant system. Finally an algorithm is presented that determines the output kurtosis based upon the input kurtosis, the input power spectral density and the frequency response function of the system. The algorithm is validated using numerical simulations. Direct applications of these results include improved fatigue life estimations and a method to accelerate shaker tests by generating high kurtosis, non-Gaussian drive signals.

Kihm, Frederic↗

NASA NTRS1979

Predictive analysis of metal fatigue in the high cyclic life range

This report summarizes various aspects of predictive approaches in high cycle fatigue, hcf. The distinction between hcf and low cycle fatigue, lcf, is discussed in relation to the transition life and strainrange, and curves are presented to establish regions wherein each range predominates depending on the properties of any material of interest. The role of loading order on hcf in cumulative damage analysis is also discussed, together with mean stress effects and their relaxation. Also briefly discussed are high temperature fatigue and ultra-high cycle fatigue.

Manson, S. S.↗

NASA NTRS1987

Fatigue damage interaction behavior of PWA 1480

The fatigue damage interaction behavior of PWA 1480 single crystal alloy has been experimentally established for the two-level loading case in which a block of low-cycle fatigue loading is followed by high-cycle fatigue loading to failure. A relative life ratio N1/N2 (where N1 and N2 are the low- and high-cycle fatigue baseline lives, respectively) of approximately 0.002 was explored to assess the interaction behavior. The experimental results thus far show evidence of a loading order interaction effect to a similar degree of detriment as has been observed in polycrystalline materials. Current generation single crystal alloys in general, and PWA 1480 in particular, contain pores; indeed, it was observed in all cases that specimen failure initiated from pores connected with or immediately below the surface. Detailed fractographic and metallographic studies are currently being made to assess the nature of the porosity in terms of its effect on fatigue life.

Mcgaw, Michael A.↗

NASA NTRS2014

Forced Response Analysis of a Fan with Boundary Layer Inlet Distortion

Boundary layer ingesting propulsion systems have the potential to significantly reduce fuel burn for future generations of commercial aircraft, but these systems must be designed to overcome the challenge of high dynamic stresses in fan blades due to forced response. High dynamic stresses can lead to high cycle fatigue failures. High-fidelity computational analysis of the fan aeromechanics is integral to an ongoing effort to design a boundary layer ingesting inlet and fan for a wind-tunnel test. An unsteady flow solution from a Reynoldsaveraged Navier Stokes analysis of a coupled inlet-fan system is used to calculate blade unsteady loading and assess forced response of the fan to distorted inflow. Conducted prior to the mechanical design of a fan, the initial forced response analyses performed in this study provide an early look at the levels of dynamic stresses that are likely to be encountered. For the boundary layer ingesting inlet, the distortion contains strong engine order excitations that act simultaneously. The combined effect of these harmonics was considered in the calculation of the forced response stresses. Together, static and dynamic stresses can provide the information necessary to evaluate whether the blades are likely to fail due to high cycle fatigue. Based on the analyses done, the overspeed condition is likely to result in the smallest stress margin in terms of the mean and alternating stresses. Additional work is ongoing to expand the analyses to off-design conditions, on-resonance conditions, and to include more detailed modeling of the blade structure.

Vibrational stress↗

DOE OSTI2022

Stress-controlled fatigue of HfNbTaTiZr high-entropy alloy and associated deformation and fracture mechanisms

The stress-controlled fatigue tests are carried out at a stress ratio of 0.1 and a frequency of 10 Hz, and span both low-cycle and high-cycle regimes by varying the applied stress amplitudes. The high-cycle fatigue regime gives a fatigue strength of 497 MPa and a fatigue ratio of 0.44. At equivalent conditions, the alloy's fatigue strength is greater than all other high-entropy alloys (HEAs) with reported high-cycle fatigue data, dilute body-centered cubic alloys, and many structural alloys such as steels, titanium alloys, and aluminum alloys. Through in-depth analyses of crack-propagation trajectories, fracture-surface morphologies and deformation plasticity by means of various microstructural analysis techniques and theoretical frameworks, the alloy's remarkable fatigue resistance is attributed to delayed crack initiation in the high-cycle regime, which is achieved by retarding the formation of localized persistent slip bands, and its good resistance to crack propagation in the low-cycle regime, which is accomplished by intrinsic toughening backed up by extrinsic toughening. Additionally, the stochastic nature of the fatigue data is neatly captured with a 2-parameter Weibull model.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Fatigue life prediction of powder bed fused–laser beam AlSi10Mg: Incorporating critical defects via crystal plasticity modelling

The current study provides a microstructurally-based computational framework to predict the fatigue life of additive manufactured (AM), i.e., powder bed fused–laser beam (PBF-LB), AlSi10Mg specimens using the crystal plasticity finite element method (CPFEM). The fractography analysis, electron backscatter diffraction (EBSD), uniaxial and cyclic responses, and fatigue life of specimens were used to inform the computational framework. CPFE simulation was used to compute fatigue indicator parameters (FIPs) as fatigue driving forces. A new fatigue criterion is introduced based on FIPs, which was calibrated using experimental fatigue data. The proposed fatigue measure was evaluated versus the specimens with critical defects of various sizes and locations subjected to different stress amplitudes. The results show that the developed framework can capture the fatigue life of samples with different critical defect locations and sizes along with different stress amplitudes for both high-cycle fatigue (HCF) and very high-cycle fatigue (VHCF) regimes.

Additive manufacturing↗

NASA NTRS2001

Laser High-Cycle Thermal Fatigue of Pulse Detonation Engine Combustor Materials Tested

Pulse detonation engines (PDE's) have received increasing attention for future aerospace propulsion applications. Because the PDE is designed for a high-frequency, intermittent detonation combustion process, extremely high gas temperatures and pressures can be realized under the nearly constant-volume combustion environment. The PDE's can potentially achieve higher thermodynamic cycle efficiency and thrust density in comparison to traditional constant-pressure combustion gas turbine engines (ref. 1). However, the development of these engines requires robust design of the engine components that must endure harsh detonation environments. In particular, the detonation combustor chamber, which is designed to sustain and confine the detonation combustion process, will experience high pressure and temperature pulses with very short durations (refs. 2 and 3). Therefore, it is of great importance to evaluate PDE combustor materials and components under simulated engine temperatures and stress conditions in the laboratory. In this study, a high-cycle thermal fatigue test rig was established at the NASA Glenn Research Center using a 1.5-kW CO2 laser. The high-power laser, operating in the pulsed mode, can be controlled at various pulse energy levels and waveform distributions. The enhanced laser pulses can be used to mimic the time-dependent temperature and pressure waves encountered in a pulsed detonation engine. Under the enhanced laser pulse condition, a maximum 7.5-kW peak power with a duration of approximately 0.1 to 0.2 msec (a spike) can be achieved, followed by a plateau region that has about one-fifth of the maximum power level with several milliseconds duration. The laser thermal fatigue rig has also been developed to adopt flat and rotating tubular specimen configurations for the simulated engine tests. More sophisticated laser optic systems can be used to simulate the spatial distributions of the temperature and shock waves in the engine. Pulse laser high-cycle thermal fatigue behavior has been investigated on a flat Haynes 188 alloy specimen, under the test condition of 30-Hz cycle frequency (33-msec pulse period and 10-msec pulse width including a 0.2-msec pulse spike; ref. 4). Temperature distributions were calculated with one-dimensional finite difference models. The calculations show that that the 0.2-msec pulse spike can cause an additional 40 C temperature fluctuation with an interaction depth of 0.08 mm near the specimen surface region. This temperature swing will be superimposed onto the temperature swing of 80 C that is induced by the 10-msec laser pulse near the 0.53-mm-deep surface interaction region.

Zhu, Dong-Ming↗

NASA NTRS1995

Probabilistic Material Strength Degradation Model for Inconel 718 Components Subjected to High Temperature, High-Cycle and Low-Cycle Mechanical Fatigue, Creep and Thermal Fatigue Effects

The development of methodology for a probabilistic material strength degradation is described. The probabilistic model, in the form of a postulated randomized multifactor equation, provides for quantification of uncertainty in the lifetime material strength of aerospace propulsion system components subjected to a number of diverse random effects. This model is embodied in the computer program entitled PROMISS, which can include up to eighteen different effects. Presently, the model includes five effects that typically reduce lifetime strength: high temperature, high-cycle mechanical fatigue, low-cycle mechanical fatigue, creep and thermal fatigue. Results, in the form of cumulative distribution functions, illustrated the sensitivity of lifetime strength to any current value of an effect. In addition, verification studies comparing predictions of high-cycle mechanical fatigue and high temperature effects with experiments are presented. Results from this limited verification study strongly supported that material degradation can be represented by randomized multifactor interaction models.

Bast, Callie C.↗

NASA NTRS1979

Technical evaluation report of the Specialists Meeting on Characterization of Low Cycle High Temperature Fatigue by the Strainrange Partitioning Method

The ability of the Strainrange Partitioning Method SRP was evaluated to correlate the creep-fatigue behavior of gas turbine materials and to predict the creep fatigue life of laboratory specimens subjected to complex cycling conditions. A reference body of high temperature creep fatigue data which can be used in the evaluation of other SRP and low cycle high temperature fatigue predictive techniques was provided.

Drapier, J. M.↗

NASA NTRS1997

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic stresses. It is found that in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗

NASA NTRS1991

The effects of multiple repairs on Inconel 718 weld mechanical properties

Inconel 718 weldments were repaired 3, 6, 9, and 13 times using the gas tungsten arc welding process. The welded panels were machined into mechanical test specimens, postweld heat treated, and nondestructively tested. Tensile properties and high cycle fatigue life were evaluated and the results compared to unrepaired weld properties. Mechanical property data were analyzed using the statistical methods of difference in means for tensile properties and difference in log means and Weibull analysis for high cycle fatigue properties. Statistical analysis performed on the data did not show a significant decrease in tensile or high cycle fatigue properties due to the repeated repairs. Some degradation was observed in all properties, however, it was minimal.

Russell, C. K.↗

NASA NTRS2011

Advanced Gear Alloys for Ultra High Strength Applications

Single tooth bending fatigue (STBF) test data of UHS Ferrium C61 and C64 alloys are presented in comparison with historical test data of conventional gear steels (9310 and Pyrowear 53) with comparable statistical analysis methods. Pitting and scoring tests of C61 and C64 are works in progress. Boeing statistical analysis of STBF test data for the four gear steels (C61, C64, 9310 and Pyrowear 53) indicates that the UHS grades exhibit increases in fatigue strength in the low cycle fatigue (LCF) regime. In the high cycle fatigue (HCF) regime, the UHS steels exhibit better mean fatigue strength endurance limit behavior (particularly as compared to Pyrowear 53). However, due to considerable scatter in the UHS test data, the anticipated overall benefits of the UHS grades in bending fatigue have not been fully demonstrated. Based on all the test data and on Boeing s analysis, C61 has been selected by Boeing as the gear steel for the final ERDS demonstrator test gearboxes. In terms of potential follow-up work, detailed physics-based, micromechanical analysis and modeling of the fatigue data would allow for a better understanding of the causes of the experimental scatter, and of the transition from high-stress LCF (surface-dominated) to low-stress HCF (subsurface-dominated) fatigue failure. Additional STBF test data and failure analysis work, particularly in the HCF regime and around the endurance limit stress, could allow for better statistical confidence and could reduce the observed effects of experimental test scatter. Finally, the need for further optimization of the residual compressive stress profiles of the UHS steels (resulting from carburization and peening) is noted, particularly for the case of the higher hardness C64 material.

Shen, Tony↗

NASA NTRS1995

Probabilistic material strength degradation model for Inconel 718 components subjected to high temperature, high-cycle and low-cycle mechanical fatigue, creep and thermal fatigue effects

This report presents the results of both the fifth and sixth year effort of a research program conducted for NASA-LeRC by The University of Texas at San Antonio (UTSA). The research included on-going development of methodology for a probabilistic material strength degradation model. The probabilistic model, in the form of a postulated randomized multifactor equation, provides for quantification of uncertainty in the lifetime material strength of aerospace propulsion system components subjected to a number of diverse random effects. This model is embodied in the computer program entitled PROMISS, which can include up to eighteen different effects. Presently, the model includes five effects that typically reduce lifetime strength: high temperature, high-cycle mechanical fatigue, low-cycle mechanical fatigue, creep and thermal fatigue. Statistical analysis was conducted on experimental Inconel 718 data obtained from the open literature. This analysis provided regression parameters for use as the model's empirical material constants, thus calibrating the model specifically for Inconel 718. Model calibration was carried out for five variables, namely, high temperature, high-cycle and low-cycle mechanical fatigue, creep and thermal fatigue. Methodology to estimate standard deviations of these material constants for input into the probabilistic material strength model was developed. Using an updated version of PROMISS, entitled PROMISS93, a sensitivity study for the combined effects of high-cycle mechanical fatigue, creep and thermal fatigue was performed. Then using the current version of PROMISS, entitled PROMISS94, a second sensitivity study including the effect of low-cycle mechanical fatigue, as well as, the three previous effects was performed. Results, in the form of cumulative distribution functions, illustrated the sensitivity of lifetime strength to any current value of an effect. In addition, verification studies comparing a combination of high-cycle mechanical fatigue and high temperature effects by model to the combination by experiment were conducted. Thus, for Inconel 718, the basic model assumption of independence between effects was evaluated. Results from this limited verification study strongly supported this assumption.

Bast, Callie C.↗

NASA NTRS2005

Rotordynamic Analysis and Feasibility Study of a Disk Spin Test Facility for Rotor Health Monitoring

Recently, National Aeronautics and Space Administration (NASA) initiated a program to achieve the significant improvement in aviation safety. One of the technical challenges is the design and development of accelerated experiments that mimic critical damage cases encountered in engine components. The Nondestructive Evaluation (NDE) Group at the NASA Glenn Research Center (GRC) is currently addressing the goal concerning propulsion health management and the development of propulsion system specific technologies intended to detect potential failures prior to catastrophe. For this goal the unique disk spin simulation system was assembled at NASA GRC, which allows testing of rotors with the spinning speeds up to 10K RPM, and at the elevated temperature environment reaching 540 C (1000 F). It is anticipated that the facility can be employed for detection of Low Cycle Fatigue disk cracking and further High Cycle Fatigue blade vibration. The controlled crack growth studies at room and elevated temperatures can be conducted on the turbine wheels, and various NDE techniques can be integrated and assessed as in-situ damage monitoring tools. Critical rotating parts in advanced gas turbine engines such as turbine disks frequently operate at high temperature and stress for long periods of time. The integrity of these parts must be proven by non-destructive evaluation (NDE) during various machining steps ranging from forging blank to finished shape, and also during the systematic overhaul inspections. Conventional NDE methods, however, have unacceptable limits. Some of these techniques are time-consuming and inconvenient for service aircraft testing. Almost all of these techniques require that the vicinity of the damage is known in advance. These experimental techniques can provide only local information and no indication of the structural strength at a component and/or system level. The shortcomings of currently available NDE methods lead to the requirement of new damage detection techniques that can provide global information on the rotating components/system, and, in addition, they do not require direct human access to the operating system. During this period of research considerable effort was directed towards the further development of experimental facility and development of the vibration-based crack detection methodology for rotating disks and shafts. A collection of papers and reports were written to describe the results of this work. The attached captures that effort and represents the research output during the grant period.

Sawicki, Jerzy T.↗