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At least 721 records · Page 40

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NASA NTRS1986

High temperature monotonic and cyclic deformation in a directionally solidified nickel-base superalloy

Directionally solidified (DS) MAR-M246+Hf was tested in tension and fatigue, at temperatures from 20 C to 1093 C. Tests were performed on (001) oriented specimens at strain rates of 50 % and 0.5 % per minute. In tension, the yield strength was constant up to 704 C, above which the strength dropped off rapidly. A strong dependence of strength on strain rate was seen at the higher temperatures. The deformation mode was observed to change from heterogeneous to homogeneous with increasing temperature. Low Cycle Fatigue tests were done using a fully reversed waveform and total strain control. For a given plastic strain range, lives increased with increasing temperature. For a given temperature strain rate had a strong effect on life. At 704 C, decreasing strain rates decreased life, while at the higher temperatures, decreasing strain rates increased life, for a given plastic strain range. These results could be explained through considerations of the deformation modes and stress levels. At the higher temperatures, marked coarsening caused beneficial stress reductions, but oxidation limited the life. The longitudinal grain boundaries were found to influence slip behavior. The degree of secondary slip adjacent to the boundaries was found to be related to the degree of misorientation between the grains.

Huron, Eric S.↗

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 NTRS1984

Dynamic response and acoustic fatigue of stiffened composite structure

The results of acoustic fatigue and dynamic response tests performed on L-1011 graphite-epoxy (GrE) aileron and panel components are reported. The aileron featured glass microballoons between the GrE skins. Tests yielded random fatigue data from double and single cantilever coupons and modal data from impedance hammer and loudspeaker impulses. Numerical and sample test data were obtained on combined acoustic and shear loads, acoustic and thermal loads, random fatigue and damping of the integrally stiffened and secondary bonded panels. The fatigue data indicate a fatigue life beyond 10 million cycles. The acoustic data suggested that noise transmission could be enhanced in the integrally stiffened panels, which were more acoustic-fatigue resistant than were the secondary bonded panels.

Soovere, J.↗

NASA NTRS2013

Evaluation of Delamination Onset and Growth Characterization Methods under Mode I Fatigue Loading

Double-cantilevered beam specimens of IM7/8552 graphite/epoxy from two different manufacturers were tested in static and fatigue to compare the material characterization data and to evaluate a proposed ASTM standard for generating Paris Law equations for delamination growth. Static results were used to generate compliance calibration constants for reducing the fatigue data, and a delamination resistance curve, GIR, for each material. Specimens were tested in fatigue at different initial cyclic GImax levels to determine a delamination onset curve and the delamination growth rate. The delamination onset curve equations were similar for the two sources. Delamination growth rate was calculated by plotting da/dN versus GImax on a log-log scale and fitting a Paris Law. Two different data reduction methods were used to calculate da/dN. To determine the effects of fiber-bridging, growth results were normalized by the delamination resistance curves. Paris Law exponents decreased by 31% to 37% after normalizing the data. Visual data records from the fatigue tests were used to calculate individual compliance constants from the fatigue data. The resulting da/dN versus GImax plots showed improved repeatability for each source, compared to using averaged static data. The Paris Law expressions for the two sources showed the closest agreement using the individually fit compliance data.

Murri, Gretchen B.↗

NASA NTRS1989

Application of fracture mechanics and half-cycle theory to the prediction of fatigue life of aerospace structural components

The service life of aircraft structural components undergoing random stress cycling was analyzed by the application of fracture mechanics. The initial crack sizes at the critical stress points for the fatigue crack growth analysis were established through proof load tests. The fatigue crack growth rates for random stress cycles were calculated using the half-cycle method. A new equation was developed for calculating the number of remaining flights for the structural components. The number of remaining flights predicted by the new equation is much lower than that predicted by the conventional equation. This report describes the application of fracture mechanics and the half-cycle method to calculate the number of remaining flights for aircraft structural components.

Ko, William L.↗

NASA NTRS1996

Standardization Activities in TMF Test Methodologies

No standard test practice currently exists for strain-controlled thermomechanical fatigue (TMF) testing. This paper discusses recent activities which lay the foundation for standardization of TMF test methods. Specifically, the paper documents the results of two interlaboratory TMF test programs, identifies key TMF symposia and workshops, and discusses efforts toward drafting a TMF standard test practice.

Verrilli, M. J.↗

NASA NTRS2005

Effects of High-Temperature Exposures on the Fatigue Life of Disk Superalloys Examined

Tests used to characterize the low-cycle-fatigue resistance of disk superalloys are usually performed at cyclic frequencies of 0.33 Hz or faster. However, service conditions for disks in some aerospace and land-based gas turbine engines can produce major cycle periods extending from minutes to hours and days. Over a service life, this can produce total service times near the maximum temperature that exceed 100 hr for aerospace applications and 100,000 hr for land-based applications. Such time-dependent effects of realistic mission cycles on fatigue resistance can be significant in superalloy disks, and need to be considered for accurate disk life prediction. The purpose of this study at the NASA Glenn Research Center was to examine the effects of extended exposures and extended cycle periods on the fatigue resistance of two disk superalloys. Current alloy Udimet 720 (Special Metals Corporation, Huntington, WV) disk material was provided by Solar Turbines/Caterpillar Co., and advanced alloy ME3 was provided by the NASA Ultra-Efficient Engine Technologies (UEET) Project, in powder-metallurgy-processed, supersolvus heat-treated form. Fatigue specimens were fully machined and exposed in air at temperatures of 650 to 704 C for extended times. Then, they were tested using conventional fatigue tests with a total strain range of 0.70 percent and a minimum-to-maximum strain ratio of zero to determine the effects of prior exposure on fatigue resistance. Subsequent tests with extended dwells at minimum strain in each fatigue cycle were performed to determine cyclic exposure effects.

Gabb, Timothy P.↗

NASA NTRS1971

Design features and results from fatigue reliability research machines

Design and performance tests for reversed bending with steady torque fatigue test machine using notched steel specimens

Lalli, V. R.↗

NASA NTRS2000

Fatigue Characterization of Alloy 10: a 1300F Disk Alloy for Small Gas Turbine Engines

A detailed fatigue characterization of Alloy 10, a high strength nickel-based disk alloy, was conducted on test coupons machined from a 'pancake' forging. Smooth bar, strain controlled fatigue testing at various R-ratios was run at representative bore, 750 F, and rim, 1300 F, temperatures. This was followed by notch fatigue testing (Kt=2) run under load control. Analysis of the fatigue data using a Smith-Watson-Topper approach and finite element analysis of the notch root was employed to understand material behavior in these tests. Smooth bar fatigue data showed a significant R-ratio dependence at either test temperature which could be accounted for using a Smith-Watson-Topper parameter (SWT). In general, fatigue life was longer at 750 F than 1300 F for a given SWT. For notch fatigue tests, life was longer at 750 F than 1300 F but only at higher stresses. This was attributed to differences in alloy strength. At lower stresses, finite element analysis suggested that convergence of fatigue life at both temperatures resulted from relaxation of stresses at the notch root in the 1300 F tests.

Gayda, John↗

NASA NTRS1992

Thermomechanical and bithermal fatigue behavior of cast B1900 + Hf and wrought Haynes 188

A thermomechanical fatigue (TMF) high-temperature life prediction method has been evaluated using the experimental data. Bithermal fatigue (BTF), bithermal creep-fatigue (BTC-F), and TMF experiments were performed using two aerospace structural alloys, cast B1900 + Hf and wrought Haynes 188. The method which is based on the total strain version of strain range partitioning and unified cyclic constitutive modeling requires, as an input, information on the flow and failure behavior of the material of interest. Bithermal temperatures of 483 and 871 C were used for the cast B1900 + Hf nickel-base alloy and 316 and 760 C for the wrought Haynes 188 cobalt-base alloy. Maximum and minimum temperatures were also used in both TMF and BTF tests. Comparisons were made between the results of these tests and isothermal tensile and fatigue test data obtained previously. Qualitative correlations were observed between tensile and isothermal fatigue tests.

Halford, G. R.↗

NASA NTRS1986

Life prediction and constitutive models for engine hot section anisotropic materials program

This report presents the results of the first year of a program designed to develop life prediction and constitutive models for two coated single crystal alloys used in gas turbine airfoils. The two alloys are PWA 1480 and Alloy 185. The two oxidation resistant coatings are PWA 273, an aluminide coating, and PWA 286, an overlay NiCoCrAlY coating. To obtain constitutive and/or fatigue data, tests were conducted on coated and uncoated PWA 1480 specimens tensilely loaded in the 100 , 110 , 111 , and 123 directions. A literature survey of constitutive models was completed for both single crystal alloys and metallic coating materials; candidate models were selected. One constitutive model under consideration for single crystal alloys applies Walker's micromechanical viscoplastic formulation to all slip systems participating in the single crystal deformation. The constitutive models for the overlay coating correlate the viscoplastic data well. For the aluminide coating, a unique test method is under development. LCF and TMF tests are underway. The two coatings caused a significant drop in fatigue life, and each produced a much different failure mechanism.

Swanson, G. A.↗

NASA NTRS2001

Disk Alloy Development

The advanced powder metallurgy disk alloy ME3 was designed using statistical screening and optimization of composition and processing variables in the NASA HSR/EPM disk program to have extended durability at 1150 to 1250 "Fin large disks. Scaled-up disks of this alloy were produced at the conclusion of this program to demonstrate these properties in realistic disk shapes. The objective of the UEET disk program was to assess the mechanical properties of these ME3 disks as functions of temperature, in order to estimate the maximum temperature capabilities of this advanced alloy. Scaled-up disks processed in the HSR/EPM Compressor / Turbine Disk program were sectioned, machined into specimens, and tested in tensile, creep, fatigue, and fatigue crack growth tests by NASA Glenn Research Center, in cooperation with General Electric Engine Company and Pratt & Whitney Aircraft Engines. Additional sub-scale disks and blanks were processed and tested to explore the effects of several processing variations on mechanical properties. Scaled-up disks of an advanced regional disk alloy, Alloy 10, were used to evaluate dual microstructure heat treatments. This allowed demonstration of an improved balance of properties in disks with higher strength and fatigue resistance in the bores and higher creep and dwell fatigue crack growth resistance in the rims. Results indicate the baseline ME3 alloy and process has 1300 to 1350 O F temperature capabilities, dependent on detailed disk and engine design property requirements. Chemistry and process enhancements show promise for further increasing temperature capabilities.

Gabb, Tim↗

NASA NTRS1983

Effect of carbide distribution on rolling-element fatigue life of AMS 5749

Endurance tests with ball bearings made of corrosion resistant bearing steel which resulted in fatigue lives much lower than were predicted are discussed. Metallurgical analysis revealed an undesirable carbide distribution in the races. It was shown in accelerated fatigue tests in the RC rig that large, banded carbides can reduce rolling element fatigue life by a factor of approximately four. The early spalling failures on the bearing raceways are attributed to the large carbide size and banded distribution.

Parker, R. J.↗

NASA NTRS2004

Detailed Microstructural Characterization of the Disk Alloy ME3

The advanced powder metallurgy disk alloy ME3 was designed using statistical screening and optimization of composition and processing variables in the NASA/General Electric/Pratt & Whitney HSR/EPM disk program to have extended durability for large disks at maximum temperatures of 600 to 700 C. Scaled-up disks of this alloy were then produced at the conclusion of that program to demonstrate these properties in realistic disk shapes. The objective of the present study was to assess the microstructural characteristics of these ME3 disks at two consistent locations, in order to enable estimation of the variations in microstructure across each disk and across several disks of this advanced alloy. Scaled-up disks processed in the HSR/EPM Compressor/Turbine Disk program had been sectioned, machined into specimens, and tested in tensile, creep, fatigue, and fatigue crack growth tests by NASA Glenn Research Center, in cooperation with General Electric Engine Company and Pratt & Whitney Aircraft Engines. For this study, microstructures of grip sections from tensile specimens in the bore and rim were evaluated from these disks. The major and minor phases were identified and quantified using transmission electron microscopy (TEM). Particular attention was directed to the .' precipitates, which along with grain size can predominantly control the mechanical properties of superalloy disks.

Gabb, Timothy P.↗

NASA NTRS2005

Fatigue Behavior and Deformation Mechanisms in Inconel 718 Superalloy Investigated

The nickel-base superalloy Inconel 718 (IN 718) is used as a structural material for a variety of components in the space shuttle main engine (SSME) and accounts for more than half of the total weight of this engine. IN 718 is the bill-of-material for the pressure vessels of nickel-hydrogen batteries for the space station. In the case of the space shuttle main engine, structural components are typically subjected to startup and shutdown load transients and occasional overloads in addition to high-frequency vibratory loads from routine operation. The nickel-hydrogen battery cells are prooftested before service and are subjected to fluctuating pressure loads during operation. In both of these applications, the structural material is subjected to a monotonic load initially, which is subsequently followed by fatigue. To assess the life of these structural components, it is necessary to determine the influence of a prior monotonic load on the subsequent fatigue life of the superalloy. An insight into the underlying deformation and damage mechanisms is also required to properly account for the interaction between the prior monotonic load and the subsequent fatigue loading. An experimental investigation was conducted to establish the effect of prior monotonic straining on the subsequent fatigue behavior of wrought, double-aged, IN 718 at room temperature. First, monotonic strain tests and fully-reversed, strain-controlled fatigue tests were conducted on uniform-gage-section IN 718 specimens. Next, fully reversed fatigue tests were conducted under strain control on specimens that were monotonically strained in tension. Results from this investigation indicated that prior monotonic straining reduced the fatigue resistance of the superalloy particularly at the lowest strain range. Some of the tested specimens were sectioned and examined by transmission electron microscopy to reveal typical microstructures as well as the active deformation and damage mechanisms under each of the loading conditions. In monotonically strained specimens, deformation during the subsequent fatigue loading was mainly confined to the deformation bands initiated during the prior monotonic straining. This can cause dislocations to move more readily along the previously activated deformation bands and to pile up near grain boundaries, eventually making the grain boundaries susceptible to fatigue crack initiation. The mechanisms inferred from the microstructural investigation were extremely valuable in interpreting the influence of prior monotonic straining on the subsequent fatigue life of Inconel 718 superalloy.

Source record↗

NASA NTRS2008

Test Population Selection from Weibull-Based, Monte Carlo Simulations of Fatigue Life

Fatigue life is probabilistic and not deterministic. Experimentally establishing the fatigue life of materials, components, and systems is both time consuming and costly. As a result, conclusions regarding fatigue life are often inferred from a statistically insufficient number of physical tests. A proposed methodology for comparing life results as a function of variability due to Weibull parameters, variability between successive trials, and variability due to size of the experimental population is presented. Using Monte Carlo simulation of randomly selected lives from a large Weibull distribution, the variation in the L10 fatigue life of aluminum alloy AL6061 rotating rod fatigue tests was determined as a function of population size. These results were compared to the L10 fatigue lives of small (10 each) populations from AL2024, AL7075 and AL6061. For aluminum alloy AL6061, a simple algebraic relationship was established for the upper and lower L10 fatigue life limits as a function of the number of specimens failed. For most engineering applications where less than 30 percent variability can be tolerated in the maximum and minimum values, at least 30 to 35 test samples are necessary. The variability of test results based on small sample sizes can be greater than actual differences, if any, that exists between materials and can result in erroneous conclusions. The fatigue life of AL2024 is statistically longer than AL6061 and AL7075. However, there is no statistical difference between the fatigue lives of AL6061 and AL7075 even though AL7075 had a fatigue life 30 percent greater than AL6061.

Vlcek, Brian L.↗

NASA NTRS2012

Test Population Selection from Weibull-Based, Monte Carlo Simulations of Fatigue Life

Vlcek, Brian L.↗

NASA NTRS2004

The Effect of Hole Quality on the Fatigue Life of 2024-T3 Aluminum Alloy Sheet

This paper presents the results of a study whose main objective was to determine which type of fabrication process would least affect the fatigue life of an open-hole structural detail. Since the open-hole detail is often the fundamental building block for determining the stress concentration of built-up structural parts, it is important to understand any factor that can affect the fatigue life of an open hole. A test program of constant-amplitude fatigue tests was conducted on five different sets of test specimens each made using a different hole fabrication process. Three of the sets used different mechanical drilling procedures while a fourth and fifth set were mechanically drilled and then chemically polished. Two sets of specimens were also tested under spectrum loading to aid in understanding the effects of residual compressive stresses on fatigue life. Three conclusions were made from this study. One, the residual compressive stresses caused by the hole-drilling process increased the fatigue life by two to three times over specimens that were chemically polished after the holes were drilled. Second, the chemical polishing process does not appear to adversely affect the fatigue life. Third, the chemical polishing process will produce a stress-state adjacent to the hole that has insignificant machining residual stresses.

Everett, Richard A., Jr.↗