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At least 757 records · Page 42

All sources NASA NTRS DOE OSTI

NASA NTRS1977

Wear formulation for aircraft brake material sliding against steel

Predictions of wear on contemporary copper-based brake material sliding against 17-22 AS grade steel, wear testing equipment, formulation of wear, and test results are discussed. An initial investigation of worn surfaces of the brake material and a mating steel rotor was carried out. A wear model proposed suggests initiation of cracks at a hard particle inclusion site in the surface layer of the brake material; crack propagation allows particles to be removed by intersection of cracks. Mutual relations between sliding variables, load, time, hardness, and surface temperature are studied. Empirical formulas are exhibited.

Ho, T. L.↗

DOE OSTI2022

Miniature Crack or Damage Detection on Cable Insulation and Jacket Using Conformal Surface Wave Reflectometry

This letter introduces the study and application of a conformal surface wave launcher array to detect miniature insulation and/or jacket damage on unshielded cables. Here simulation and experimental results are presented that demonstrate that with the proposed concept very small instances of damage at various distances along power cables can be detected. Effects of damage detection feasibility in the presence of other cables in proximity and for cables containing semiconducting screen are also presented.

42 ENGINEERING↗

NASA NTRS2010

Nondestructive Crack Detection in a Fuel System Component

The paper discusses development of various NDE techniques to detect cracks in A40 steel poppets used in a valve of the fuel system of the Space Shuttle Orbiter. The valve assembly experiences a severe high cycle fatigue environment during its operation. Cracks were discovered at the radius of the poppet flange. Experience shows that very small cracks or material anomalies do not cause failure in a single operation event. While the design is being modified to eliminate the issue, NDE has been used to screen the poppets for cracks before every use. Several surface flaw detection techniques were considered and a few NDE techniques were developed to provide NDE screening for the flaw detection. The primary method used was the eddy current testing. In the eddy current technique, the X-Y channel test data from the eddy current instrument was recorded as computer files. A Matlab data review and plotting application was developed to analyze the data files. The Matlab application provides much higher resolution than the eddy current instrument that was used to acquire the data. Other techniques that were used included ultrasonic surface wave and magnetic particle testing. A probability of detection (POD) study was undertaken to determine the 90/95 size for the eddy current technique. This study used specimens with same geometry and material as the poppet. Fatigue cracks were grown in these specimens. Information on results of the NDE techniques and results of the POD study are provided.

Koshti, Ajay↗

NASA NTRS1979

Detection of hairline cracks in textured silicon solar cells

Using a focused laser scanner, the optical technique described in the present paper can be used to detect hairline cracks of the type occurring in solar cells subjected to surface texturing. The technique is capable of detecting cracks of the order of a few microns, which, otherwise, can be observed only under high magnification using an optical microscope. The technique consists of scanning a solar cell with a finely focused laser beam and recording the photoresponse (short circuit current or open circuit voltage) as a function of beam position. The presence of a crack is manifested by a sharp dip in the photoresponse.

Sopori, B. L.↗

NASA NTRS1921

Causes of Cracking of Ignition Cable

The experiments described here show that the cracking at sharp bends, observed in the insulation of internal combustion engine high tension ignition wires after service, is due to a chemical attack upon the rubber by the ozone produced by the electric discharge that takes place at the surface of the cable. This cracking does not occur if the insulating material is not under tension, or if the cable is surrounded by some medium other than air. But it does occur even if the insulation is not subjected to electric stress, provided that the atmosphere near the cable contains ozone. The extent of this cracking varies greatly with the insulating material used. The cracking can be materially reduced by using braided cable and by avoiding sharp bends.

Silsbee, F B↗

NASA NTRS2005

Development of Detectability Limits for On-Orbit Inspection of Space Shuttle Wing Leading Edge

At the conclusion of the Columbia Accident Investigation, one of the recommendations of the Columbia Accident Investigation Board (CAIB) was that NASA develop and implement an inspection plan for the Reinforced Carbon-Carbon (RCC) system components of the Space Shuttle. To address these issues, a group of scientists and engineers at NASA Langley Research Center proposed the use of an IR camera to inspect the RCC. Any crack in an RCC panel changes the thermal resistance of the material in the direction perpendicular to the crack. The change in thermal resistance can be made visible by introducing a heat flow across the crack and using an IR camera to image the resulting surface temperature distribution. The temperature difference across the crack depends on the change in the thermal resistance, the length of the crack, the local thermal gradient, and the rate of radiation exchange with the environment. This paper describes how the authors derived the minimum thermal gradient detectability limits for a through crack in an RCC panel. This paper will also show, through the use of a transient, 3-dimensional, finite element model, that these minimum gradients naturally exist on-orbit. The results from the finite element model confirm that there are sufficient thermal gradient to detect a crack on 96% of the RCC leading edge.

Stephan, Ryan A.↗

NASA NTRS1978

Friction and wear behavior of single-crystal silicon carbide in sliding contact with various metals

Sliding friction experiments were conducted with single-crystal silicon carbide in contact with various metals. Results indicate the coefficient of friction is related to the relative chemical activity of the metals. The more active the metal, the higher the coefficient of friction. All the metals examined transferred to silicon carbide. The chemical activity of the metal and its shear modulus may play important roles in metal transfer, the form of the wear debris and the surface roughness of the metal wear scar. The more active the metal, and the less resistance to shear, the greater the transfer to silicon carbide and the rougher the wear scar on the surface of the metal. Hexagon shaped cracking and fracturing formed by cleavage of both prismatic and basal planes is observed on the silicon carbide surface.

Miyoshi, K.↗

NASA NTRS1988

Boundary element method for 3-D cracks in a plate

Fundamental solutions which automatically satisfy boundary conditions at the interfaces of an elastic plate perfectly bonded to two elastic halfspaces are implemented in a three-dimensional BEM for crack problems. The BEM features a new integration scheme for highly singular kernels. The capability is achieved through a part analytic and part numerical integration procedure, such that the analytic part of the integration is similar for all slip/opening variations. Part-through elliptic cracks in an elastic plate with traction-free surfaces are analyzed and the SIF values along the crack front are found to compare favorably with the numerical SIF results of Raju and Newman (1979).

Fares, N.↗

NASA NTRS1990

On the variation in crack-opening stresses at different locations in a three-dimensional body

Crack propagation and closure behavior of thin, and thick middle crack tension specimens under constant amplitude loading were investigated using a three dimensional elastic plastic finite element analysis of fatigue crack propagation and closure. In the thin specimens the crack front closed first on the exterior (free) surface and closed last in the interior during the unloading portion of cyclic loading; a load reduced displacement technique was used to determine crack opening stresses at specified locations in the plate from the displacements calculated after the seven cycle. All the locations were on the plate external surface and were located near the crack tip, behind the crack tip, at the centerline of the crack. With this technique, the opening stresses at the specified points were found to be 0.52, 0.42, and 0.39 times the maximum applied stress.

Chermahini, R. G.↗

NASA NTRS1984

Three-dimensional measurements of fatigue crack closure

Three dimensional fatigue crack opening profiles in transparent polymer test specimens were determined. The load required to separate crack faces was measured along the crack profile at various positions through the specimens thickness. Crack opening loads at the specimen surface (under plane stress conditions) were compared with measurements made under plane strain conditions the specimen interior. The fatigue crack opening load was correlated with fatigue crack retardation behavior caused by peak overloads, and the results discussed in terms of three dimensional aspects of the fatigue crack closure mechanism for fatigue crack retardation.

Grandt, A. F., Jr.↗

NASA NTRS2006

Flow Liner Slot Edge Replication Feasibility Study

Surface replication has been proposed as a method for crack detection in space shuttle main engine flowliner slots. The results of a feasibility study show that examination of surface replicas with a scanning electron microscope can result in the detection of cracks as small as 0.005 inch, and surface flaws as small as 0.001 inch, for the flowliner material.

Newman, John A.↗

NASA NTRS1999

Use of Several Thermal Analysis Techniques on a Hypalon Paint Coating for the Solid Rocket Booster (SRB) of the Space Shuttle

White Hypalon paint is brush-applied as a moisture barrier coating over cork surfaces on each of the two Space Shuttle SRBS. Fine cracks have been observed in the Hypalon coating three times historically on laboratory witness panels, but never on flight hardware. Recent samples of the cracked and standard ("good") Hypalon were removed from cork surfaces and were tested by Thermal Gravimetric Analysis (TGA), Thermomechanical (TMA) and Differential Scanning Calorimetry (DSC) thermal analysis techniques. The TGA data showed that at 700 C, where only paint pigment solids remain, the cracked material had about 9 weight percent more material remaining than the standard material, probably indicating incomplete mixing of the paint before it was brush-applied to produce the cracked material. Use of the TMA film tension method showed that the average static modulus vs. temperature was about 3 to 6 times higher for the cracked material than for the standard material, indicating a much higher stiffness for the cracked Hypalon. The TMA data also showed than an increased coating thickness for the cracked Hypalon was not a factor in the anomaly.

Wingard, Charles D.↗

DOE OSTI2022

Fracture mechanisms of sodium silicate glasses

Reactive classical molecular dynamics simulations of sodium silicate glasses, xNa 2 O–(100 – x)SiO 2 (x = 10–30), under quasi-static loading, were performed for the analysis of molecular scale fracture mechanisms. Mechanical properties of the sodium silicate glasses were consistent with experimentally reported values, and the amount of crack propagation varied with reported fracture toughness values. The most crack propagation occurred in NS20 systems (20-mol% Na 2 O) compared with the other simulated compositions. Dissipation via two mechanisms, the first through sodium migration as a lower activation energy process and the second through structural rearrangement as a higher activation energy process, was calculated and accounted for the energy that was not stored elastically or associated with the formation of new fracture surfaces. Here, a correlation between crack propagation and energy dissipation was identified, with systems with higher crack propagation exhibiting less energy dissipation. Sodium silicate glass compositions with lower energy dissipation also exhibited the most sodium movement and structural rearrangement within 10 Å of the crack tip during loading. Therefore, high sodium mobility near the crack tip may enable energy dissipation without requiring formation of structural defects. Therefore, the varying mobilities of the network modifiers near crack tips influence the brittleness and the crack growth rate of modified amorphous oxide systems.

36 MATERIALS SCIENCE↗

NASA NTRS2013

On the Theory and Numerical Simulation of Cohesive Crack Propagation with Application to Fiber-Reinforced Composites

The phenomenon of crack propagation is among the predominant modes of failure in many natural and engineering structures, often leading to severe loss of structural integrity and catastrophic failure. Thus, the ability to understand and a priori simulate the evolution of this failure mode has been one of the cornerstones of applied mechanics and structural engineering and is broadly referred to as "fracture mechanics." The work reported herein focuses on extending this understanding, in the context of through-thickness crack propagation in cohesive materials, through the development of a continuum-level multiscale numerical framework, which represents cracks as displacement discontinuities across a surface of zero measure. This report presents the relevant theory, mathematical framework, numerical modeling, and experimental investigations of through-thickness crack propagation in fiber-reinforced composites using the Variational Multiscale Cohesive Method (VMCM) developed by the authors.

Rudraraju, Siva Shankar↗

NASA NTRS1993

A study of subsurface crack initiation produced by rolling contact fatigue

Results of subsurface crack initiation studies produced by pure rolling contact fatigue in 7075-T6 aluminum alloy are presented in this article. Microstructural changes and subsequent crack initiation below the contacting surface in cylindrical test specimens subjected to repeated rolling contact are illustrated. The rolling conditions are simulated in a three-dimensional elastic-plastic finite element model in order to estimate the plastic strains and residual stresses in the test material. The numerically estimated distribution of plastic strains in the model correlate well with the extent of microstructural changes observed in the test specimen. Results also indicate that a combination of plastic strains and low values of residual stresses is conducive to subsurface crack initiation and growth.

Kumar, Arun M.↗

DOE OSTI2021

Transparent silica aerogel slabs synthesized from nanoparticle colloidal suspensions at near ambient conditions on omniphobic liquid substrates

This paper presents a novel sol-gel method to synthesize large and thick silica aerogel monoliths at near ambient conditions using a commercial aqueous solution of colloidal silica nanoparticles as building blocks. To achieve slabs with high visible transmittance and low thermal conductivity, the method combines the strategies of (i) synthesizing gels on an omniphobic perfluorocarbon liquid substrate, (ii) aging at temperatures above room temperature, and (iii) performing solvent exchange with a low-surface-tension organic solvent prior to ambient drying. The omniphobic liquid substrates were used to prevent cracking and ensure an optically-smooth surface, while nanoparticle building blocks were small (<10 nm) to limit volumetric light scattering. Gels were aged at temperatures between 25 and 80 °C for up to 21 days to make them stronger and stiffer and to reduce shrinkage and cracking during ambient drying. Ambient drying was achieved by first exchanging water in the gel pores for octane, followed by drying in an octane-rich atmosphere to decrease capillary forces. The synthesized nanoparticle-based silica aerogel monoliths had thicknesses up to 5 mm, diameters up to 10 cm, porosities exceeding 80%, and thermal conductivities as low as 0.08 W m –1 K –1 . Notably, the slabs featured visible transmittance exceeding 75% even for slabs as thick as 5 mm. The as-synthesized aerogel monoliths were exposed to TMCS vapor to induce hydrophobic properties resulting in a water contact angle of 140° that prevented water infiltration into the pores and protected the aerogels from water damage. This simple synthesis route conducted at near ambient conditions produces hydrophobic aerogel monoliths with promising optically transparent and thermally insulating properties that can be adhered to glass panes for window insulation and solar-thermal energy conversion applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2006

Crack Initiation and Growth in Rigid Polymeric Closed-Cell Foam Cryogenic Applications

Cryogenic vessels, such as the Space Shuttle External Tank, are often insulated with closed-cell foam because of its low thermal conductivity. The coefficient of thermal expansion mismatch between the foam and metallic substrate places the foam under a biaxial tension gradient through the foam thickness. The total foam thickness affects the slope of the stress gradient and is considered a significant contributor to the initiation of subsurface cracks. Rigid polymeric foams are brittle in nature and any subsurface cracks tend to propagate a finite distance toward the surface. This presentation investigates the relationship between foam thickness and crack initiation and subsequent crack growth, using linear elastic fracture mechanics, in a rigid polymeric closed-cell foam through analysis and comparison with experimental results.

Sayyah, Tarek↗

DOE OSTI2020

Structural integrity of additively manufactured stainless steel with cold sprayed barrier coating under combined cyclic loading

Integration of metal additive manufacturing (AM) and cold spray (CS) technologies provide an unprecedented opportunity to manufacture coated material systems with complex geometrical features. The application of these material systems in functionally critical components requires adequate structural integrity, particularly in the presence of cyclic loading. This article researches the multiaxial fatigue (axial-torsional cyclic loading) behavior of a coated material system consisting of 15Cr-5Ni precipitation-hardening stainless steel (15-5 PH SS) substrate additively manufactured by direct metal laser sintering with a layer of chromium carbide nickel (CrC-Ni) barrier coating deposited by CS. The influence of AM and CS-induced residual stresses on fatigue performance of test specimens was thoroughly studied. Additionally, the effect of surface roughness and processes induced defects were considered to explain the crack growth mechanism. Stresses assessed by synchrotron X-ray diffraction indicated a substantial accumulation of residual stresses, particularly in the outer surface of the as-fabricated 155 PH SS specimens. The state of residual stress was changed notably following the deposition of CrC-Ni coating in the axial, hoop, and radial directions of the fatigue test specimen. Also, CS deposition of CrC-Ni coating caused significant improvement in the surface quality of the additively manufactured components. Fatigue test results indicated, CS deposition of CrC-Ni substantially enhances the fatigue life of the AM-produced 15-5 PH SS substrate in all loading conditions, particularly in the high cycle fatigue regime. The improvement in the fatigue life of the specimens with coating was associated with a reduction in equivalent residual stress at the substrate surface and improvement in the specimens' surface condition (i.e., reduced surface roughness). The fractographic analysis of the specimen indicated the cracks tend to initiate in the surface of both as-fabricated and cold-sprayed specimens. However, the mechanism of crack growth changed notably following the deposition of CrC-Ni coating. The cracks tended to propagate in the planes parallel or with a small deviation from the build layers of the AM-produced specimens. On the other hand, deposition of CrC-Ni coating increased the deviation of crack growth plane from the build layers of the substrate.

36 MATERIALS SCIENCE↗