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All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Three Dimensional Constraint Effects on the Estimated (Delta)CTOD during the Numerical Simulation of Different Fatigue Threshold Testing Techniques

Variation in constraint through the thickness of a specimen effects the cyclic crack-tip-opening displacement (DELTA CTOD). DELTA CTOD is a valuable measure of crack growth behavior, indicating closure development, constraint variations and load history effects. Fatigue loading with a continual load reduction was used to simulate the load history associated with fatigue crack growth threshold measurements. The constraint effect on the estimated DELTA CTOD is studied by carrying out three-dimensional elastic-plastic finite element simulations. The analysis involves numerical simulation of different standard fatigue threshold test schemes to determine how each test scheme affects DELTA CTOD. The American Society for Testing and Materials (ASTM) prescribes standard load reduction procedures for threshold testing using either the constant stress ratio (R) or constant maximum stress intensity (K(sub max)) methods. Different specimen types defined in the standard, namely the compact tension, C(T), and middle cracked tension, M(T), specimens were used in this simulation. The threshold simulations were conducted with different initial K(sub max) values to study its effect on estimated DELTA CTOD. During each simulation, the DELTA CTOD was estimated at every load increment during the load reduction procedure. Previous numerical simulation results indicate that the constant R load reduction method generates a plastic wake resulting in remote crack closure during unloading. Upon reloading, this remote contact location was observed to remain in contact well after the crack tip was fully open. The final region to open is located at the point at which the load reduction was initiated and at the free surface of the specimen. However, simulations carried out using the constant Kmax load reduction procedure did not indicate remote crack closure. Previous analysis results using various starting K(sub max) values and different load reduction rates have indicated DELTA CTOD is independent of specimen size. A study of the effect of specimen thickness and geometry on the measured DELTA CTOD for various load reduction procedures and its implication in the estimation of fatigue crack growth threshold values is discussed.

Seshadri, Banavara R.↗
NASA NTRS1986

An assessment of the small-crack effect for 2024-T3 aluminum alloy

Data on small-crack behavior were obtained for a single-edge-notched tensile specimen made of 2024-T3 Al alloy and used to evaluate the capability of a semiempirical crack-growth and closure model to predict the fatigue life of notched specimens. Fatigue tests were conducted under either constant-amplitude loading (with stress ratios of 0.5, 0, -1, and -2) or spectrum loading, using a replication technique to record growth. It was found that small cracks exhibited the 'small-crack' effect in that they grew faster than large cracks when subjected to the same stress intensity factor range. Experimental small-crack growth rates agreed well with the model predictions. For making predictions of fatigue life, an initial surface defect void size of 3 x 12 x 0.4 microns was used in all calculations; predicted fatigue lives agreed well with experimentally determined values obtained in all tests. The crack-closure model indicated that the 'small-crack' effect on fatigue life was greatest in tests involving significant compressive loads.

Newman, J. C., Jr.↗
NASA NTRS2003

Leak Location and Classification in the Space Shuttle Main Engine Nozzle by Infrared Testing

The Space Shuttle Main Engine (SSME) is composed of cooling tubes brazed to the inside of a conical structural jacket. Because of the geometry there are regions that can't be inspected for leaks using the bubble solution and low-pressure method. The temperature change due escaping gas is detectable on the surface of the nozzle under the correct conditions. The methods and results presented in this summary address the thermographic identification of leaks in the Space Shuttle Main Engine nozzles. A highly sensitive digital infrared camera is used to record the minute temperature change associated with a leak source, such as a crack or pinhole, hidden within the nozzle wall by observing the inner "hot wall" surface as the nozzle is pressurized. These images are enhanced by digitally subtracting a thermal reference image taken before pressurization, greatly diminishing background noise. The method provides a nonintrusive way of localizing the tube that is leaking and the exact leak source position to within a very small axial distance. Many of the factors that influence the inspectability of the nozzle are addressed; including pressure rate, peak pressure, gas type, ambient temperature and surface preparation.

Russell, Samuel S.↗
NASA NTRS1990

Holographic Reticle

Holographic reticle proposed for use in nondestructive evaluation of surface irregularities. Extends inspection capability to include measurements of depth. Surfaces inspected without contamination, damage, or costly disassembly. Provides valuable information difficult to obtain. For example, surface defects as corrosion and porosity, as well as propagation of cracks, measured accurately. Roughness, wear, and plating thickness also measured. Also used to determine quality of microcircuits.

Henn, Edward A.↗
NASA NTRS1992

Damage mechanisms in three-dimensional woven reinforced ceramic matrix composites under tensile and flexural loading at room and elevated temperatures

Three-dimensional Nicalon SiC/SiC matrix composites made through a chemical vapor infiltration process were studied under tensile and flexural loading at 23, 1200, and 1550 C in air. In situ damage accumulation monitoring NDE techniques were utilized to identify failure mechanisms in these materials. The effectiveness and durability of a chemical vapor deposition SiC surface coating were also evaluated in severe oxidizing environment. Results show that the failure response was very similar for the 23 and 1200 C specimens, while at 1550 C there were significant changes in both the composite mechanical behavior and the matrix microstructure. Extensive fiber pull-out was observed only in the 1550 C specimen. It is also found that the SiC surface coating can protect the composite up to the critical matrix cracking strength.

Chulya, Abhisak↗
NASA NTRS2002

Nodal Constraint, Shear Deformation and Continuity Effects Related to the Modeling of Debonding of Laminates, Using Plate Elements

The effects of several critical assumptions and parameters on the computation of strain energy release rates for delamination and debond configurations modeled with plate elements have been quantified. The method of calculation is based on the virtual crack closure technique (VCCT), and models of the upper and lower surface of the delamination or debond that use two-dimensional (2D) plate elements rather than three-dimensional (3D) solid elements. The major advantages of the plate element modeling technique are a smaller model size and simpler configurational modeling. Specific issues that are discussed include: constraint of translational degrees of freedom, rotational degrees of freedom or both in the neighborhood of the debond front, shear deformation assumptions; and continuity of material properties and section stiffness in the vicinity of the debond front. Where appropriate, the plate element analyses are compared with corresponding two-dimensional plane strain analyses.

Glaessgen, E. H.↗
NASA NTRS2002

Shergottite Impact Melt Glasses Contain Soil from Martian Uplands

Martian meteorite (shergottite) impact melt glasses that contain high concentrations of martian atmospheric noble gases and show significant variations in Sr-87/Sr-86 isotopic ratios are likely to contain Martian surface fines mixed with coarser regolith materials. The mixed soil constituents were molten due to shock at the time of meteoroid impact near the Martian surface and the molten glass got incorporated into the voids and cracks in some shergottite meteorites. Earlier, Rao et al. found large enrichments of sulfur (sulfate) during an electron-microprobe study of several impact melt glass veins and pods in EET79001,LithC thin sections. As sulfur is very abundant in Martian soil, these S excesses were attributed to the mixing of a soil component containing aqueously altered secondary minerals with the LithC precursor materials prior to impact melt generation. Recently, we studied additional impact melt glasses in two basaltic shergottites, Zagami and Shergotty using procedures similar to those described by Rao et al. Significant S enrichments in Zagami and Shergotty impact melt glass veins similar to the EET79001, LithC glasses were found. In addition, we noticed the depletion of the mafic component accompanied by the enrichment of felsic component in these impact melt glass veins relative to the bulk host rock in the shergottites. To explain these observations, we present a model based on comminution of basaltic rocks due to meteroid bombardment on martian regolith and mechanical fractionation leading to enrichment of felsics and depletion of mafics in the fine grained dust which is locally mobilized as a result of saltation and deflation due to the pervasive aeolian activity on Mars.

Rao, M. N.↗
NASA NTRS2002

Shergottite Impact Melt Glasses Contain Soil from Martian Uplands

Martian meteorite (shergottite) impact melt glasses that contain high concentrations of martian atmospheric noble gases and show significant variations in Sr-87/Sr-86 isotopic ratios are likely to contain Martian surface fines mixed with coarser regolith materials. The mixed soil constituents were molten due to shock at the time of meteoroid impact near the Martian surface and the molten glass got incorporated into the voids and cracks in some shergottite meteorites. Earlier, Rao et al. found large enrichments of sulfur (sulfate) during an electron-microprobe study of several impact melt glass veins and pods in EET79001,LithC thin sections. As sulfur is very abundant in Martian soil, these S excesses were attributed to the mixing of a soil component containing aqueously altered secondary minerals with the LithC precursor materials prior to impact melt generation. Recently, we studied additional impact melt glasses in two basaltic shergottites, Zagami and Shergotty using procedures similar to those described. Significant S enrichments in Zagami and Shergotty impact melt glass veins similar to the EET79001, LithC glasses were found. In addition, we noticed the depletion of the mafic component accompanied by the enrichment of felsic component in these impact melt glass veins relative to the bulk host rock in the shergottites. To explain these observations, we present a model based on comminution of basaltic rocks due to meteoroid bombardment on martian regolith and mechanical fractionation leading to enrichment of felsics and depletion of mafics in the fine grained dust which is locally mobilized as a result of saltation and deflation due to the pervasive aeolian activity on Mars.

Rao, M. N.↗
NASA NTRS2019

Electron Beam Welding of Pure Tungsten Hex Cans for Nuclear Thermal Propulsion Engines

Nuclear thermal propulsion (NTP) is an in-space propulsion method currently being developed at the NASA Marshall Space Flight Center (MSFC). NTP systems are a high specific impulse (750–1,100 s), high thrust (15,000–250,000 lbf ) method of propulsion which have the potential to allow for faster transit times when optimizing for high ΔV. In the nuclear rocket engine, the heat from the nuclear fission reaction is transferred to a low molecular mass propellant (such as hydrogen). Hot propellant is expanded through a nozzle to generate thrust. Development of ceramic metal (cermet) fuel systems for NTP applications is currently ongoing at MSFC. In cermet fuel systems, ceramic fissile fuel particles such as uranium nitride or uranium dioxide are dispersed within a net-shaped, high-density structural matrix. The composite material is cladded by a protective metal structure to make up an NTP fuel element. Cladding materials must be able to withstand the demanding operating conditions required of the engine as well as retain a hermetic seal to allow for retention of fuel element structural integrity, prevent hydrogen attack or migration of the ceramic fuel, and limit release of fission products during operation. For NTP applications, tungsten is a prime material for both the metal matrix and cladding in cermet fuel systems because of its high melting point, high temperature strength, and compatibility with hot hydrogen. If a weld in tungsten with the capability of holding a hermetic seal is achievable, tungsten becomes a strong candidate for NTP applications. This Technical Memorandum focuses on determining the weldability of pure tungsten using electron beam welding (EBW). Tungsten appears well suited for NTP applications, but it has a high ductile to brittle transition temperature (DBTT) dependent upon chemical composition, structure/stress distribution, and mechanical conditions. Therefore, it is highly subject to brittle fracture. Because of its high susceptibility to brittle fracture, it is very difficult to weld. EBW was chosen for joining pure tungsten because of its low heat input compared to gas tungsten arc welding. Reduced heat input can be directly correlated with an increase in ductility of a tungsten weld. EBW is a high energy density welding process in which a stream of electrons penetrates a weld joint in a deep, narrow spike in contrast to a broad gas tungsten arc weld pool. The investigation initially focused on EBW of tungsten plates of both 0.01 in and 0.03 in thickness to determine if EBW could weld pure tungsten without the presence of visual defects—particularly cracking—in the welds. Variation in the weld procedure and post-weld heat treatment (PWHT) was used to improve the surface appearance of flat EBWs on a pure tungsten sheet. The investigation moved on to weld 0.05-in-thick hexagonal tungsten cans with a weld joint thickness of 0.025 in. The goal for welding the pure tungsten hex cans was to avoid any visual surface defects and generate a weld capable of a hermetic seal. This proved difficult. Cold welds commonly exhibited porosity that leaked air. Hot welds exhibited cracks, typically observed immediately after welding. Later welds were preheated to increase ductility and decrease the likelihood of through-thickness cracking. PWHT was used to arrest microcrack growth both in the flat weld samples and hexagonal weld samples.

Courtright, Z. S.↗
NASA NTRS1993

Quality Factor and Microslipping of Fatigue Cracks in Thin Plates at Resonant Vibration

Resonant vibrations have been stimulated in thin metal plates using a non-contacting electromagnetic driver. A sinusoidal force was applied in a swept frequency fashion and the resulting surface displacements were monitored through the use of an acoustic microphone. It has been found that the presence of a fatigue crack in the sample causes a broadening of the second resonance peak. The Q factors of the resonance curves were determined and are directly correlated with the presence of fatigue cracks in the samples. The broadening of the curves is explained in terms of a microslipping at the crack face walls which reduces the amplitude of the resonant vibration by increasing the damping of the system. A comparison is made between the resonance characteristics of fatigue damaged and notched samples, where the stiffness of the two systems is nearly constant while the interaction between crack face walls is eliminated in the latter.

Wincheski, B.↗
NASA NTRS1980

Hybrid-finite-element analysis of some nonlinear and 3-dimensional problems of engineering fracture mechanics

In this paper, efficient numerical methods for the analysis of crack-closure effects on fatigue-crack-growth-rates, in plane stress situations, and for the solution of stress-intensity factors for arbitrary shaped surface flaws in pressure vessels, are presented. For the former problem, an elastic-plastic finite element procedure valid for the case of finite deformation gradients is developed and crack growth is simulated by the translation of near-crack-tip elements with embedded plastic singularities. For the latter problem, an embedded-elastic-singularity hybrid finite element method, which leads to a direct evaluation of K-factors, is employed.

Atluri, S. N.↗
NASA NTRS2011

Statistical Analysis of an Infrared Thermography Inspection of Reinforced Carbon-Carbon

Each piece of flight hardware being used on the shuttle must be analyzed and pass NASA requirements before the shuttle is ready for launch. One tool used to detect cracks that lie within flight hardware is Infrared Flash Thermography. This is a non-destructive testing technique which uses an intense flash of light to heat up the surface of a material after which an Infrared camera is used to record the cooling of the material. Since cracks within the material obstruct the natural heat flow through the material, they are visible when viewing the data from the Infrared camera. We used Ecotherm, a software program, to collect data pertaining to the delaminations and analyzed the data using Ecotherm and University of Dayton Log Logistic Probability of Detection (POD) Software. The goal was to reproduce the statistical analysis produced by the University of Dayton software, by using scatter plots, log transforms, and residuals to test the assumption of normality for the residuals.

Comeaux, Kayla↗
NASA NTRS1992

Determination of high temperature strains using a PC based vision system

With the widespread availability of video digitizers and cheap personal computers, the use of computer vision as an experimental tool is becoming common place. These systems are being used to make a wide variety of measurements that range from simple surface characterization to velocity profiles. The Sub-Pixel Digital Image Correlation technique has been developed to measure full field displacement and gradients of the surface of an object subjected to a driving force. The technique has shown its utility by measuring the deformation and movement of objects that range from simple translation to fluid velocity profiles to crack tip deformation of solid rocket fuel. This technique has recently been improved and used to measure the surface displacement field of an object at high temperature. The development of a PC based Sub-Pixel Digital Image Correlation system has yielded an accurate and easy to use system for measuring surface displacements and gradients. Experiments have been performed to show the system is viable for measuring thermal strain.

Mcneill, Stephen R.↗
NASA NTRS1992

Radar-anomalous, high-altitude features on Venus

Over nearly all of the surface of Venus the reflectivity and emissivity at centimeter wavelengths are about 0.15 and 0.85 respectively. These values are consistent with moderately dense soils and rock populations, but the mean reflectivity is about a factor of 2 greater than that for the Moon and other terrestrial planets. Pettingill and Ford, using Pioneer Venus reflectivities and emissivities, found a number of anomalous features on Venus that showed much higher reflectivities and much lower emissivities with both values approaching 0.5. These include Maxwell Montes, a number of high regions in Aphrodite Terra and Beta Regio, and several isolated mountain peaks. Most of the features are at altitudes above the mean radius by 2 to 3 km or more. However, such features have been found in the Magellan data at low altitudes and the anomalies do not exist on all high structures, Maat Mons being the most outstanding example. A number of papers have been written that attempt to explain the phenomena in terms of the geochemistry balance of weathering effects on likely surface minerals. The geochemists have shown that the fundamentally basaltic surface would be stable at the temperatures and pressures of the mean radius in the form of magnetite, but would evolve to pyrite and/or pyrrhotite in the presence of sulfur-bearing compounds such as SO2. Pyrite will be stable at altitudes above 4 or 5 km on Venus. Although the geochemical arguments are rather compelling, it is vitally important to rationally look at other explanations for radar and radio emission measurements such as that presented by Tryka and Muhleman. The radar reflectivity values are retrieved from the raw Magellan backscatter measurements by fitting the Hagfors' radar scattering model in which a surface roughness parameters and a normal incidence electrical reflectivity are estimated. The assumptions of the theory behind the model must be considered carefully before the results can be believed. These include that the surface roughness exists only at horizontal scales large compared to the wavelength, the vertical deviations are gaussianly distributed, there is no shadowing, and that the reflection occurs at the interface of two homogeneous dielectric half-spaces. Probably all these conditions are violated at the anomalous features under discussion. The most important of these is the homogeneity of the near surface of Venus, particularly in highlands. Under the assumptions of the theory, all of the radio energy is reflected by the impedance jump at the very boundary. However, in heterogeneous soil some fraction of the illuminating energy is propagated into the soil and then scattered back out by impedance discontinuities such as rock, voids, and cracks. In light soils, the latter effect can overwhelm the scattering effects of the true surface and greatly enhance the backscatter power, suggesting a much higher value of an effective dielectric constant that would be estimated from Hagfors' model.

Muhleman, Duane O.↗
NASA NTRS1971

Stress corrosion cracking of titanium alloys

Experiments were conducted to study (1) the basic electrochemical behavior of titanium in acid chloride solutions and (2) the response of the metal to dynamic straining in the same evironment. The aim of this group of experiments was to simulate, as nearly as possible, the actual conditions which exist at the tip of a crack. One of the foremost theories proposed to explain the propagation of stress corrosion cracks is a hydrogen embrittlement theory involving the precipitation of embrittling titanium hydrides inside the metal near the crack tip. An initial survey of the basic electrochemical literature indicated that surface hydrides play a critical role in the electrochemistry of titanium in acid solutions. A comprehensive analysis of the effect of surface films, particularly hydrides, on the electrochemical behavior of titanium in these solution is presented.

May, R. C.↗
NASA NTRS1982

Solution of naturally-ocurring glasses in the geological environment

As part of a study to investigate the feasibility of putting nuclear wastes in glass containers and burying them on land or dumping them in the ocean, the amount of solution experience by naturally occurring glasses from two land sites and thirty-four deep sea sites was studied. The glasses are microtektites from three strewn fields and from the Zhamanshin impact crater. The microtektites range in age from 0.7 to 35 m.y. and have a wide range in composition. The weight percent SiO2, for example, ranges from 44.8 to 81.7. Although several criteria for determining the amount of solution were considered, most of the conclusions are based on two criteria: (1) width of cracks, and (2) elevation of silica rich inclusions above the adjacent microtektite surface. All the measurements were made on scanning electron microscope photomicrographs of the microtektites.

Glass, B. P.↗
NASA NTRS1983

Stress-corrosion behavior of aluminum-lithium alloys in aqueous environments

The stress corrosion susceptibility of two powder metallurgy (P/M) alloys, Al-Li-Cu and Al-Li-Cu-Mg two mechanically attrited (M/A) alloys, Al-Li-Cu and Al-Li-Mg; and two wrought, ingot alloys, X-2020 and AA7475, are compared. Time-dependent fracture in an aqueous sodium chloride environment under alternate immersion condition was found to vary significantly between alloys. The stress corrosion behavior of the two powder metallurgy processed alloys was studied in detail under conditions of crack initiation, static crack growth, and fatigue crack growth. A variety of stress corrosion tests were performed including smooth surface, time-to-failure tests; potentiostatic tests on smooth surfaces exposed to constant applied strain rates; and fracture mechanics-type tests under static and cyclic loads. Both alloys show surface pitting and subsequent intergranular corrosion. Pitting is more severe in the magnesium-bearing alloy and is associated with stringer particles strung along the extrusion direction as a result of P/M processing.

Pizzo, P. P.↗