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At least 775 records · Page 43

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NASA NTRS1998

Continuum Damage Mechanics Used to Predict the Creep Life of Monolithic Ceramics

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated temperature applications. High-temperature and long-duration applications of monolithic ceramics can place their failure mode in the creep rupture regime. An analytical methodology in the form of the integrated design program-Ceramics Analysis and Reliability Evaluation of Structures/Creep (CARES/Creep) has been developed by the NASA Lewis Research Center to predict the life of ceramic structural components subjected to creep rupture conditions. This program utilizes commercially available finite element packages and takes into account the transient state of stress and creep strain distributions (stress relaxation as well as the asymmetric response to tension and compression). The creep life of a component is discretized into short time steps, during which the stress distribution is assumed constant. Then, the damage is calculated for each time step on the basis of a modified Monkman-Grant (MMG) creep rupture criterion. The cumulative damage is subsequently calculated as time elapses in a manner similar to Miner's rule for cyclic fatigue loading. Failure is assumed to occur when the normalized cumulative damage at any point in the component reaches unity. The corresponding time is the creep rupture life for that component.

Powers, Lynn M.↗

NASA NTRS1993

Fatigue life and crack growth prediction methodology

The capabilities of a plasticity-induced crack-closure model and life-prediction code to predict fatigue crack growth and fatigue lives of metallic materials are reviewed. Crack-tip constraint factors, to account for three-dimensional effects, were selected to correlate large-crack growth rate data as a function of the effective-stress-intensity factor range (delta(K(sub eff))) under constant-amplitude loading. Some modifications to the delta(K(sub eff))-rate relations were needed in the near threshold regime to fit small-crack growth rate behavior and endurance limits. The model was then used to calculate small- and large-crack growth rates, and in some cases total fatigue lives, for several aluminum and titanium alloys under constant-amplitude, variable-amplitude, and spectrum loading. Fatigue lives were calculated using the crack growth relations and microstructural features like those that initiated cracks. Results from the tests and analyses agreed well.

Newman, J. C., Jr.↗

NASA NTRS1994

Fatigue life and crack growth prediction methodology

This paper reviews the capabilities of a plasticity-induced crack-closure model and life-prediction code to predict fatigue crack growth and fatigue lives of metallic materials. Crack-tip constraint factors, to account for three-dimensional effects, were selected to correlate large-crack growth rate data as a function of the effective stress-intensity factor range (Delta K(sub eff)) under constant amplitude loading. Some modifications to the Delta K(sub eff)-rate relations were needed in the near threshold regime to fit small-crackgrowth rate behavior and endurance limits. The model was then used to calculate small- and large-crack growth rates, and in some cases total fatigue lives, for several aluminum and titanium alloys under constant-amplitude, variable-amplitude, and spectrum loading. Fatigue lives were calculated using the crack-growth relations and microstructural features like those that initiated cracks. Results from the tests and analyses agreed well.

Newman, J. C., Jr.↗

DOE OSTI2025

Combined Creep and Fatigue Modeling

Simultaneous consideration of creep and fatigue is of paramount importance to accurately predict component life in many industrial applications. For example, growing penetration of renewable energy onto the grid is forcing many power plants to transition from base-load power generation to more complex operation modes, characterized by a combination of base-load generation and frequent start-up and shut-down cycles. The frequent start-stop of power plants is causing a significant toll in the component life due to fatigue. As such, creep alone is not adequate anymore to predict the component life. Most existing life prediction models consider creep or fatigue independently while neglect their interactions. In this presentation, we talk about some recent efforts at NETL to develop a unified modeling framework where both creep and fatigue can be considered. The creep-fatigue interaction mechanism is studied. High-throughput simulations are performed under various hold stress and hold time, and analytical expressions are fitted for the crack growth rates under creep and/or fatigue conditions demonstrating some applications of this newly developed modeling capability.

advanced alloy development↗

NASA NTRS1990

A model for predicting damage induced fatigue life of laminated composite structural components

This paper presents a model for predicting the life of laminated composite structural components subjected to fatigue induced microstructural damage. The model uses the concept of continuum damage mechanics, wherein the effects of microcracks are incorporated into a damage dependent lamination theory instead of treating each crack as an internal boundary. Internal variables are formulated to account for the effects of both matrix cracks and internal delaminations. Evolution laws for determining the damage variables as functions of ply stresses are proposed, and comparisons of predicted damage evolution are made to experiment. In addition, predicted stiffness losses, as well as ply stresses are shown as functions of damage state for a variety of stacking sequences.

Allen, David H.↗

NASA NTRS1999

Probabilistic Analysis of Aircraft Gas Turbine Disk Life and Reliability

Two series of low cycle fatigue (LCF) test data for two groups of different aircraft gas turbine engine compressor disk geometries were reanalyzed and compared using Weibull statistics. Both groups of disks were manufactured from titanium (Ti-6Al-4V) alloy. A NASA Glenn Research Center developed probabilistic computer code Probable Cause was used to predict disk life and reliability. A material-life factor A was determined for titanium (Ti-6Al-4V) alloy based upon fatigue disk data and successfully applied to predict the life of the disks as a function of speed. A comparison was made with the currently used life prediction method based upon crack growth rate. Applying an endurance limit to the computer code did not significantly affect the predicted lives under engine operating conditions. Failure location prediction correlates with those experimentally observed in the LCF tests. A reasonable correlation was obtained between the predicted disk lives using the Probable Cause code and a modified crack growth method for life prediction. Both methods slightly overpredict life for one disk group and significantly under predict it for the other.

Melis, Matthew E.↗

NASA NTRS2006

Extended Aging Theories for Predictions of Safe Operational Life of Critical Airborne Structural Components

The previously developed Ko closed-form aging theory has been reformulated into a more compact mathematical form for easier application. A new equivalent loading theory and empirical loading theories have also been developed and incorporated into the revised Ko aging theory for the prediction of a safe operational life of airborne failure-critical structural components. The new set of aging and loading theories were applied to predict the safe number of flights for the B-52B aircraft to carry a launch vehicle, the structural life of critical components consumed by load excursion to proof load value, and the ground-sitting life of B-52B pylon failure-critical structural components. A special life prediction method was developed for the preflight predictions of operational life of failure-critical structural components of the B-52H pylon system, for which no flight data are available.

Ko, William L.↗

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 NTRS1987

Prediction of service life of aircraft structural components using the half-cycle method

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.

Ko, William L.↗

NASA NTRS2011

End-of-Life Optical Property Predictions of White Conductive Thermal Control Coatings through Analysis of On-Orbit and Ground Based Testing Data

New system requirements pertaining to thermal optical properties and coating electrical properties are commonly specified on non-low earth orbit missions. An increasing number of projects are specifying coatings with a surface resistivity of less than lE-9 ohm/square to mitigate electrostatic charge buildup events over a range of operational temperatures. There are a limited number of coatings that. meet these electrical property requirements while having flight derived optical properties in representative environments. Goddard Space Flight Center Code 546, Contamination and Thermal Coatings Group has recently explored the variety of electrically conductive white coatings available through domestic vendors to evaluate properties to meet project requirements in a geostationary orbit. The lack of significant flight data in representative environments required the careful selection of samples in ground based tests to establish end of life thermal properties. Attention must be given to the origin and pedigree of samples used on past on-orbit experiments to insure that the present formulations for the materials are similar and will react in similar manner.

Hasegawa, Mark↗

NASA NTRS1985

Application of two creep fatigue life models for the prediction of elevated temperature crack initiation of a nickel base alloy

Cyclic Damage Accumulation (CDA) and Total Strain-Strain Range Partitioning (TS-SRP) models for predicting the creep-fatigue crack initiation life of high temperature alloys are presented. The models differ in their fundamental assumptions regarding the controlling parameters for fatigue crack initiation and in the amount of data required to determine model constants. The CDA model represents a ductility exhaustion approach and uses stress quantities to calculate the cyclic fatigue damage. The TS-SRP model is based on the use of total mechanical strain and earlier concepts of the Strain Range Partitioning Method. Both models were applied to a well controlled fatigue data set at a high temperature nickel base alloy, B1900 + Hf, tested at 1600 F and 1800 F. The tests were divided into a baseline data set required to determine model constants and a verification data set for evaluation of the predictive capability of the models. Both models correlated the baseline data set to within factors of two in life, and predicted the verification data set to within a factor of three or better. In addition, sample calculations to demonstrate the application of each model and discusions of the predictive capabilities and areas requiring further development are presented.

Moreno, V.↗

NASA NTRS1979

Development of an Accelerated Test Design for Predicting the Service Life of the Solar Array at Mead, Nebraska

Potential long-term degradation modes for the two types of modules in the Mead array were determined and judgments were made as to those environmental stresses and combinations of stresses which accelerate the degradation of the power output. Hierarchical trees representing the severity of effects of stresses (test conditions) on eleven individual degradation modes were constructed and were pruned of tests judged to be nonessential. Composites of those trees were developed so that there is now one pruned tree covering eight degradation modes, another covering two degradation modes, and a third covering one degradation mode. These three composite trees form the basis for selection of test conditions in the final test plan which is now being prepared.

Gaines, G. B.↗

NASA NTRS1984

Prediction of Battery Life and Behavior from Analysis of Voltage Data

A method for simulating charge and discharge characteristics of secondary batteries is discussed. The analysis utilizes a nonlinear regression technique where empirical data is computer fitted with a five coefficient nonlinear equation. The equations for charge and discharge voltage are identical except for a change of sign before the second and third terms.

Mcdermott, P. P.↗

NASA NTRS1989

Application of fracture mechanics and half-cycle method to the prediction of fatigue life of B-52 aircraft pylon components

Stress intensity levels at various parts of the NASA B-52 carrier aircraft pylon were examined for the case when the pylon store was the space shuttle solid rocket booster drop test vehicle. Eight critical stress points were selected for the pylon fatigue analysis. Using fracture mechanics and the half-cycle theory (directly or indirectly) for the calculations of fatigue-crack growth ,the remaining fatigue life (number of flights left) was estimated for each critical part. It was found that the two rear hooks had relatively short fatigue life and that the front hook had the shortest fatigue life of all the parts analyzed. The rest of the pylon parts were found to be noncritical because of their extremely long fatigue life associated with the low operational stress levels.

Ko, W. L.↗

DOE OSTI2023

A verification study of fatigue-based methods in API RP 1183 for estimating fatigue life of pipeline dents

Pipeline dents are mechanical damage caused by a third party in buried pipelines during construction or maintenance repair. Dents are recognized as a leading cause of pipeline failures for both liquid and gas transmission lines, and their assessment and management are critical to pipeline integrity. To meet the industry need, American Institute of Petroleum (API) in 2020 published a recommended practice (RP) 1183 – Assessment and Management of Pipeline Dents. This API code provides the pipeline industry “standard methods” for evaluating severity and fatigue life of pipeline dents with a single peak. This paper performed an initial verification study of fatigue-based methods prescribed in API RP 1183 for estimating fatigue life of pipeline dents. A brief review was first given to the dent fatigue-based methods, including three dent screening methods for estimating dent fatigue life in Sections 7.4.1, 7.4.2, and 7.4.3 of API 1183 and one dent assessment method for predicting fatigue life in Section 8.3.4. In order to verify these fatigue life prediction methods, a set of “standard examples” of dents provided in Annexes A.1 to A.5 of API RP 1183 were utilized in this study to calculate fatigue life, to determine restraint condition, and to evaluate both screening and assessment methods for single-peak dents. Through detailed calculations and comparisons, this study confirmed some specifications of API RP 1183, but also found some self-inconsistences and errors existing in this new API code. Furthermore, this includes the self-inconsistences between three screening methods and the self-inconsistence between the screening and assessment methods. On this basis, recommendations were made on how the operators should use API RP 1183, and what actions API should take to improve this code.

42 ENGINEERING↗

NASA NTRS1985

Fatigue life analysis of a turboprop reduction gearbox

A fatigue life analysis of the Allison T56/501 turboprop reduction gearbox was developed. The life and reliability of the gearbox was based on the lives and reliabilities of the main power train bearings and gears. The bearing and gear lives were determined using the Lundberg-Palmgren theory and a mission profile. The five planet bearing set had the shortest calculated life among the various gearbox components, which agreed with field experience where the planet bearing had the greatest incidences of failure. The analytical predictions of relative lives among the various bearings were in reasonable agreement with field experience. The predicted gearbox life was in excellent agreement with field data when the material life adjustment factors alone were used. The gearbox had a lower predicted life in comparison with field data when no life adjustment factors were used or when lubrication life adjustment factors were used either alone or in combination with the material factors.

Lewicki, D. G.↗

NASA NTRS1986

Fatigue life analysis of a turboprop reduction gearbox

Lewicki, D. G.↗

NASA NTRS1984

Prediction Model for the Life of Nickel-cadmium Batteries in Geosynchronous Orbit Satellites

A mathematical model is described which predicts the service life of nickel-cadmium batteries designed for geosynchronous orbit satellites. Regression analysis technique is used to analyze orbital data on second generation trickle charged batteries. The model gives average cell voltage as a function of design parameters, operating parameters and time. The voltage model has the properties of providing a good fit to the data, good predictive capability, and agreement with known battery performance characteristics. Average cell voltage can be predicted to within 0.02 volts for up to 8 years. This modeling shows that these batteries will operate reliably for 10 years. Third-generation batteries are expected to operate even longer.

Engleman, J. H.↗