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At least 73 records · Page 4

A comparison of fatigue life prediction methodologies for rotorcraft

Because of the current U.S. Army requirement that all new rotorcraft be designed to a 'six nines' reliability on fatigue life, this study was undertaken to assess the accuracy of the current safe life philosophy using the nominal stress Palmgrem-Miner linear cumulative damage rule to predict the fatigue life of rotorcraft dynamic components. It has been shown that this methodology can predict fatigue lives that differ from test lives by more than two orders of magnitude. A further objective of this work was to compare the accuracy of this methodology to another safe life method called the local strain approach as well as to a method which predicts fatigue life based solely on crack growth data. Spectrum fatigue tests were run on notched (k(sub t) = 3.2) specimens made of 4340 steel using the Felix/28 tests fairly well, being slightly on the unconservative side of the test data. The crack growth method, which is based on 'small crack' crack growth data and a crack-closure model, also predicted the fatigue lives very well with the predicted lives being slightly longer that the mean test lives but within the experimental scatter band. The crack growth model was also able to predict the change in test lives produced by the rainflow reconstructed spectra.

Everett, R. A., Jr.↗

Hydrogen effects on low-cycle fatigue of the single-crystal nickel-base superalloy CMSX-2

The effects of hydrogen on the low-cycle fatigue behavior of CMSX-2 (001)-oriented single crystals were examined. Fatigue tests were conducted under constant plastic strain amplitude control. Cyclic stress-strain curves and fatigue life data at different plastic strain amplitudes were determined for hydrogen-free and hydrogen-charged specimens. Two charging procedures, leading to different hydrogen concentrations, were applied. Hydrogen was found to decrease significantly the number of cycles to failure under the various experimental conditions. The increasing hydrogen concentration and ratio of the hydrogen to nonhydrogen-containing volume were found to shorten fatigue life in hydrogen-charged specimens. Based on the analysis of cyclic stress-strain curves and optical and transmission electron microscopy, it was established that hydrogen enhanced strain localization and promoted crystallographic stage I cracking, leading to embrittlement.

Dollar, M.↗

A real time neural net estimator of fatigue life

A neural network architecture is proposed to estimate, in real-time, the fatigue life of mechanical components, as part of the intelligent Control System for Reusable Rocket Engines. Arbitrary component loading values were used as input to train a two hidden-layer feedforward neural net to estimate component fatigue damage. The ability of the net to learn, based on a local strain approach, the mapping between load sequence and fatigue damage has been demonstrated for a uniaxial specimen. Because of its demonstrated performance, the neural computation may be extended to complex cases where the loads are biaxial or triaxial, and the geometry of the component is complex (e.g., turbopumps blades). The generality of the approach is such that load/damage mappings can be directly extracted from experimental data without requiring any knowledge of the stress/strain profile of the component. In addition, the parallel network architecture allows real-time life calculations even for high-frequency vibrations. Owing to its distributed nature, the neural implementation will be robust and reliable, enabling its use in hostile environments such as rocket engines.

Troudet, T.↗

Observations of fatigue crack initiation and damage growth in notched titanium matrix composites

The purpose was to characterize damage initiation and growth in notched titanium matrix composites at room temperature. Double edge notched or center open hole SCS-6/Ti-15-3 specimens containing 0 deg plies or containing both 0 and 90 deg plies were fatigued. The specimens were tested in the as-fabricated (ASF) and in heat-treated conditions. A local strain criterion using unnotched specimen fatigue data was successful in predicting fatigue damage initiation. The initiation stress level was accurately predicted for both a double edge notched unidirectional specimen and a cross-plied center hole specimen. The fatigue produced long multiple cracks growing from the notches. These fatigue cracks were only in the matrix material and did not break the fibers in their path. The combination of matrix cracking and fiber/matrix debonding appears to greatly reduce the stress concentration around the notches. The laminates that were heat treated showed a different crack growth pattern. In the ASF specimens, matrix cracks had a more tortuous path and showed considerable more crack branching. For the same specimen geometry and cyclic stress, the (0/90/0) laminate with a hole had far superior fatigue resistance than the matrix only specimen with a hole.

Naik, Rajiv A.↗

X-Ray And Acoustic Measurements Yield Stiffnesses

Analytical technique combines ultrasonic scanning measurements of local velocity of sound in specimen of material with x-ray computed tomographic measurements of local mass density to compute local stiffness of material. Stiffnesses at various locations in specimen then used in finite-element mathematical model of elastic behavior of specimen to compute local stresses, local strains, and overall deformations. Technique enhances value of quantitative nondestructive x-ray and ultrasonic measurements. Especially useful in characterization of carbon/carbon composites and other advanced materials not homogeneous and for which customary simplifying assumption of constant density and/or constant stiffness not valid.

Madaras, Eric Irvine↗

Verification of rain-flow reconstructions of a variable amplitude load history

The suitability of using rain-flow reconstructions as an alternative to an original loading spectrum for component fatigue life testing is investigated. A modified helicopter maneuver history is used for the rain-flow cycle counting and history regenerations. Experimental testing on a notched test specimen over a wide range of loads produces similar lives for the original history and the reconstructions. The test lives also agree with a simplified local strain analysis performed on the specimen utilizing the rain-flow cycle count. The rain-flow reconstruction technique is shown to be a viable test spectrum alternative to storing the complete original load history, especially in saving computer storage space and processing time. A description of the regeneration method, the simplified life prediction analysis, and the experimental methods are included in the investigation.

Clothiaux, John D.↗

Stochastic modeling of turbulent reacting flows

Direct numerical simulations of a single-step irreversible chemical reaction with non-premixed reactants in forced isotropic turbulence at R(sub lambda) = 63, Da = 4.0, and Sc = 0.7 were made using 128 Fourier modes to obtain joint probability density functions (pdfs) and other statistical information to parameterize and test a Fokker-Planck turbulent mixing model. Preliminary results indicate that the modeled gradient stretching term for an inert scalar is independent of the initial conditions of the scalar field. The conditional pdf of scalar gradient magnitudes is found to be a function of the scalar until the reaction is largely completed. Alignment of concentration gradients with local strain rate and other features of the flow were also investigated.

Fox, R. O.↗

Continuum Fatigue Damage Modeling for Use in Life Extending Control

This paper develops a simplified continuum (continuous wrp to time, stress, etc.) fatigue damage model for use in Life Extending Controls (LEC) studies. The work is based on zero mean stress local strain cyclic damage modeling. New nonlinear explicit equation forms of cyclic damage in terms of stress amplitude are derived to facilitate the continuum modeling. Stress based continuum models are derived. Extension to plastic strain-strain rate models are also presented. Application of these models to LEC applications is considered. Progress toward a nonzero mean stress based continuum model is presented. Also, new nonlinear explicit equation forms in terms of stress amplitude are also derived for this case.

Lorenzo, Carl F.↗

Unique considerations in the design and experimental evaluation of tailored wings with elastically produced chordwise camber

Some of the unique considerations that are associated with the design and experimental evaluation of chordwise deformable wing structures are addressed. Since chordwise elastic camber deformations are desired and must be free to develop, traditional rib concepts and experimental methodology cannot be used. New rib design concepts are presented and discussed. An experimental methodology based upon the use of a flexible sling support and load application system has been created and utilized to evaluate a model box beam experimentally. Experimental data correlate extremely well with design analysis predictions based upon a beam model for the global properties of camber compliance and spanwise bending compliance. Local strain measurements exhibit trends in agreement with intuition and theory but depart slightly from theoretical perfection based upon beam-like behavior alone. It is conjectured that some additional refinement of experimental technique is needed to explain or eliminate these (minor) departures from asymmetric behavior of upper and lower box cover strains. Overall, a solid basis for the design of box structures based upon the bending method of elastic camber production has been confirmed by the experiments.

Rehfield, Lawrence W.↗

Continuum Fatigue Damage Modeling for Critical Design, Control, and Fault Prognosis

This paper develops a simplified continuum (continuous with respect to time, stress, etc.) fatigue damage model for use in critical design, Life Extending Control and fault prognosis. The work is based on the local strain cyclic damage modeling method. New nonlinear explicit equation forms of cyclic damage in terms of stress amplitude are derived to facilitate the continuum modelling. Stress based continuum models are derived. Extension to plastic strain-strain rate models is also presented. Progress toward a non-zero mean stress based is presented. Also new nonlinear explicit equation forms in terms of stress amplitude are derived for this case. Application of the various models to design, control, and fault prognosis is considered.

Lorenzo, Carl F.↗

Loads and Deformations of Buckled Rectangular Plates

The nonlinear large-deflection equations of von Karman for plates are converted into a set of linear equations by expanding the displacements Into a power series in terms of an arbitrary parameter. The postbuckling behavior of simply supported rectangular plates subjected to longitudinal compression and subject to a uniform temperature rise is investigated in detail by solving the first few of the equations. Experimental data are presented for the compression problem. Comparisons are made for total shortening and local strains and deflections which indicate good agreement between experimental and theoretical results.

Stein, Manuel↗

Impact Cratering Calculations

This research is computational /theoretical and complements the Caltech experimental program. We have developed an understanding of the basic physical processes and produced computational models and implemented these into Eulerian and Lagrangian finite element codes. The key issues we have addressed include the conditions required for: faulting (strain localization), elastic moduli weakening, dynamic weakening (layering elastic instabilities and fluidization), bulking (creation of porosity at zero pressure) and compaction of pores, frictional melting (creation of pseudotachylytes), partial and selective devolatilization of materials (e.g. CaCO3, water/ice mixtures), and debris flows.

Ahrens, Thomas J.↗

User's Manual and Final Report for Hot-SMAC GUI Development

A new software package called Higher Order Theory-Structural/Micro Analysis Code (HOT-SMAC) has been developed as an effective alternative to the finite element approach for Functionally Graded Material (FGM) modeling. HOT-SMAC is a self-contained package including pre- and post-processing through an intuitive graphical user interface, along with the well-established Higher Order Theory for Functionally Graded Materials (HOTFGM) thermomechanical analysis engine. This document represents a Getting Started/User's Manual for HOT-SMAC and a final report for its development. First, the features of the software are presented in a simple step-by-step example where a HOT-SMAC model representing a functionally graded material is created, mechanical and thermal boundary conditions are applied, the model is analyzed and results are reviewed. In a second step-by-step example, a HOT-SMAC model of an actively cooled metallic channel with ceramic thermal barrier coating is built and analyzed. HOT-SMAC results from this model are compared to recently published results (NASA/TM-2001-210702) for two grid densities. Finally, a prototype integration of HOTSMAC with the commercially available HyperSizer(R) structural analysis and sizing software is presented. In this integration, local strain results from HyperSizer's structural analysis are fed to a detailed HOT-SMAC model of the flange-to-facesheet bond region of a stiffened panel. HOT-SMAC is then used to determine the peak shear and peel (normal) stresses between the facesheet and bonded flange of the panel and determine the "free edge" effects.

Yarrington, Phil↗

Geologic Evolution of the Martian Dichotomy in the Ismenius Area of Mars and Implications for Plains Magnetization

The origin of the Martian dichotomy, which divides highlands from lowlands, is unknown. We examine a section of the dichotomy ( 50 - 90E) defined by steep scarps and normal faults. Stratigraphy and age relationships preclude the formation of the 2.5 km high boundary via erosion. The abrupt disappearance of topographic knobs similar to 300 - 500 km to the northeast is interpreted as a buried fault. Alignment of the buried fault with grabens, stratigraphy, and age determinations using crater counts indicate that the lowland bench is down faulted highlands crust. The estimated local strain (3.5%) and fault pattern are broadly consistent with gravitational relaxation of a plateau boundary. Magnetic and gravity anomalies occur on either side of the buried fault. Admittance analysis indicates isostatic compensation. Although nonunique, a model with a 10 km thick intracrustal block under the lowland bench, a 20 km thick block under the plains, and an excess density of 200 kg/m(3) provides a good fit to the isostatic anomaly. A good fit to a profile of the magnetic field perpendicular to the dichotomy is produced using uniformly polarized intracrustal blocks 10 - 20 km thick, an intensity of 6 Am/m, a field inclination of -30 degrees, and gaps aligned with the isostatic anomalies. One interpretation is that high-density intrusions demagnetized the crust after dynamo cessation and that low-lying magnetized areas could be down faulted highlands crust. Another model (inclination of 30 degrees) has magnetized crust beneath the isostatic anomalies, separated by gaps. The gaps could result from hydrothermal alteration of the crust along fault zones.

faulting↗

Hypervelocity Impact of Unstressed and Stressed Titanium in a Whipple Configuration in Support of the Orion Crew Exploration Vehicle Service Module Propellant Tanks

Hypervelocity impacts were performed on six unstressed and six stressed titanium coupons with aluminium shielding in order to assess the effects of the partial penetration damage on the post impact micromechanical properties of titanium and on the residual strength after impact. This work is performed in support of the definition of the penetration criteria of the propellant tanks surfaces for the service module of the crew exploration vehicle where such a criterion is based on testing and analyses rather than on historical precedence. The objective of this work is to assess the effects of applied biaxial stress on the damage dynamics and morphology. The crater statistics revealed minute differences between stressed and unstressed coupon damage. The post impact residual stress analyses showed that the titanium strength properties were generally unchanged for the unstressed coupons when compared with undamaged titanium. However, high localized strains were shown near the craters during the tensile tests.

Nahra, Henry K.↗

Hypervelocity Impact of Unstressed and Stressed Titanium in a Whipple Configuration in Support of the Orion Crew Exploration Vehicle Service Module Propellant Tanks

Hypervelocity impacts were performed on six unstressed and six stressed titanium coupons with aluminium: shielding in order to assess the effects of the partial penetration damage on the post impact micromechanical properties of titanium and on the residual strength after impact. This work is performed in support of the defInition of the penetration criteria of the propellant and oxidizer tanks dome surfaces for the service module of the crew exploration vehicle where such a criterion is based on testing and analyses rather than on historical precedence. The objective of this work is to assess the effects of applied biaxial stress on the damage dynamics and morphology. The crater statistics revealed minute differences between stressed and unstressed coupon damage. The post impact residual stress analyses showed that the titanium strength properties were generally unchanged for the unstressed coupons when compared with undamaged titanium. However, high localized strains were shown near the craters during the tensile tests.

Nahra, Henry K.↗

Numerical Predictions of Damage and Failure in Carbon Fiber Reinforced Laminates Using a Thermodynamically-Based Work Potential Theory

A thermodynamically-based work potential theory for modeling progressive damage and failure in fiber-reinforced laminates is presented. The current, multiple-internal state variable (ISV) formulation, referred to as enhanced Schapery theory (EST), utilizes separate ISVs for modeling the effects of damage and failure. Consistent characteristic lengths are introduced into the formulation to govern the evolution of the failure ISVs. Using the stationarity of the total work potential with respect to each ISV, a set of thermodynamically consistent evolution equations for the ISVs are derived. The theory is implemented into a commercial finite element code. The model is verified against experimental results from two laminated, T800/3900-2 panels containing a central notch and different fiber-orientation stacking sequences. Global load versus displacement, global load versus local strain gage data, and macroscopic failure paths obtained from the models are compared against the experimental results.

composite materials↗

Computational Modeling and Experimental Characterization of Martensitic Transformations in Nicoal for Self-Sensing Materials

Fundamental changes to aero-vehicle management require the utilization of automated health monitoring of vehicle structural components. A novel method is the use of self-sensing materials, which contain embedded sensory particles (SP). SPs are micron-sized pieces of shape-memory alloy that undergo transformation when the local strain reaches a prescribed threshold. The transformation is a result of a spontaneous rearrangement of the atoms in the crystal lattice under intensified stress near damaged locations, generating acoustic waves of a specific spectrum that can be detected by a suitably placed sensor. The sensitivity of the method depends on the strength of the emitted signal and its propagation through the material. To study the transition behavior of the sensory particle inside a metal matrix under load, a simulation approach based on a coupled atomistic-continuum model is used. The simulation results indicate a strong dependence of the particle's pseudoelastic response on its crystallographic orientation with respect to the loading direction and suggest possible ways of optimizing particle sensitivity. The technology of embedded sensory particles will serve as the key element in an autonomous structural health monitoring system that will constantly monitor for damage initiation in service, which will enable quick detection of unforeseen damage initiation in real-time and during onground inspections.

Wallace, T. A.↗