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At least 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Nucleation and growth of rolling contact failure of 440C bearing steel

A 'two-body' elasto-plastic finite element model of 2-dimensional rolling and rolling-plus-sliding was developed to treat the effect of surface irregularities. The model consists of a smooth cylinder in contact with a semi-infinite half-space that is either smooth or fitted with one of 0.4 microns deep or 7 microns deep groove, or a 0.4 microns high ridge-like asperity. The model incorporates elastic-linear-kinematic hardening-plastic (ELKP) and non-linear-kinematic hardening-plastic (NLKP) material constitutive relations appropriate for hardened bearing steel and the 440C grade. The calculated contact pressure distribution is Hertzian for smooth body contact, and it displays intense, stationary, pressure spikes superposed on the Hertzian pressure for contact with the grooved and ridged surface. The results obtained for the 0.4 microns deep groove compare well with those reported by Elsharkawy and Hamrock for an EHD lubricated contact. The effect of translating the counterface on the half space as opposed to indenting the half space with the counter face with no translation is studied. The stress and strain values near the surface are found to be similar for the two cases, whereas they are significantly different in the subsurface. It is seen that when tiny shoulders are introduced at the edge of the groove in the finite element model, the incremental plasticity and residual stresses are significantly higher in the vicinity of the right shoulder (rolling direction is from left to right) than at the left shoulder. This may explain the experimental observation that the spall nucleation occurs at the exit end of the artificially planted indents. Pure rolling calculations are compared with rolling + sliding calculations. For a coefficient of friction, mu = 0.1, the effect of friction is found to be small. Efforts were made to identify the material constitutive relations which best describe the deformation characteristics of the bearing steels in the initial few cycles. Elastic-linear-kinematic hardening-plastic (ELKP) material constitutive relations produce less net plastic deformation in the initial stages for a given stress, than seen in experiments. A new set of constitutive relations: non-linear-kinematic hardening-plastic (NLKP) was used. This material model produces more plasticity than the ELKP model and shows promise for treating the net distortions in the early stages. Techniques for performing experimental measurements that can be compared with the finite element calculations were devised. The measurements are being performed on 9mm-diameter, 440C steel cylindrical rolling elements in contact with 12.5 mm-diameter, 52100 steel balls in a 3-ball-rod fatigue test machine operating at 3600 RPM. Artificial, 7 microns deep, indents were inserted on the running track of the cylindrical rolling elements and profilometer measurements of these indents made, before and after the rolling. These preliminary measurements show that the indents are substantially deformed plastically in the process of rolling. The deformations of the groove calculated with the finite element model are comparable to those measured experimentally.

Gupta, V.↗
NASA NTRS1995

Working toward a three-dimensional fatigue closure model for surface cracks

The first reliable elastic fracture mechanics solutions for a surface crack in a plate were obtained by Newman and Raju. The authors, both from the Mechanics of Materials Branch at NASA-Langley, used a highly detailed finite element solution requiring substantial computational resources. Computers have since become more powerful and available; however, many important related problems remain computationally expensive. The problem of three-dimensional fatigue crack growth taking into account plasticity-induced crack closure is one such problem. It is the goal of this research to provide an efficient method to account for three-dimensional crack closure in fatigue. Newman developed a two-dimensional plasticity-induced crack closure model for center cracked specimens. This model requires iterations to determine both the contact solution at each growth step and the extent of the plastic zone at the crack tip. A three-dimensional version of this model would require obtaining these nonlinear variables all along the crack front. This model must be efficient so that repeated calculations can be performed during crack growth simulations. The highly versatile line spring model (LSM) with contact, fatigue, and plasticity will form the basis of the closure model. There are several required additions to past work to address the three-dimensional crack closure problem. Initially, these additions will include (1) an improved LSM to more accurately obtain the crack opening displacement, stress intensity factors, and elastic T-stress near the ends of the surface crack; (2) a method to determine the extent of the plastic zone all along the crack front; (3) a method to determine the contact zone given a perfectly plastic layer of material on the crack surfaces; (4) a method to determine the magnitude of the compressive contact stress; and (5) a way to implement the degree of constraint along the curved crack front. During the summer ASEE program an enhanced LSM was developed. A method similar to that of 'strip synthesis' first introduced by Fujimoto was used. Briefly, the crack opening displacements of 'slices' of the surface crack in a direction parallel to the plate surface are considered in addition to the standard LSM approach that makes use of springs obtained from slices perpendicular to the plate surface. This enhancement is necessary so that an accurate three-dimensional representation of quantities such as contact zone size, plastic zone size, stress intensity factors, T-stress, and crack opening displacement can be determined. By combining results of previous investigations with the LSM, the problem of three-dimensional crack closure will be addressed. In addition to a closure model, the enhanced LSM can be used for many other problems including interacting surface cracks and fatigue crack growth of a through crack with a curved crack front.

Joseph, Paul F.↗
NASA NTRS2003

The Effect of Spaceflight on the Ultrastructure of the Cerebellum

In weightlessness, astronauts and cosmonauts may experience postural illusions as well as motion sickness symptoms known as the space adaptation syndrome. Upon return to Earth, they have irregularities in posture and balance. The adaptation to microgravity and subsequent re-adaptation to Earth occurs over several days. At the cellular level, a process called neuronal plasticity may mediate this adaptation. The term plasticity refers to the flexibility and modifiability in the architecture and functions of the nervous system. In fact, plastic changes are thought to underlie not just behavioral adaptation, but also the more generalized phenomena of learning and memory. The goal of this experiment was to identify some of the structural alterations that occur in the rat brain during the sensory and motor adaptation to microgravity. One brain region where plasticity has been studied extensively is the cerebellar cortex-a structure thought to be critical for motor control, coordination, the timing of movements, and, most relevant to the present experiment, motor learning. Also, there are direct as well as indirect connections between projections from the gravity-sensing otolith organs and several subregions of the cerebellum. We tested the hypothesis that alterations in the ultrastructural (the structure within the cell) architecture of rat cerebellar cortex occur during the early period of adaptation to microgravity, as the cerebellum adapts to the absence of the usual gravitational inputs. The results show ultrastructural evidence for neuronal plasticity in the central nervous system of adult rats after 24 hours of spaceflight. Qualitative studies conducted on tissue from the cerebellar cortex (specifically, the nodulus of the cerebellum) indicate that ultrastructural signs of plasticity are present in the cerebellar zones that receive input from the gravity-sensing organs in the inner ear (the otoliths). These changes are not observed in this region in cagematched ground control animals. The specific changes include the formation of lamellar bodies, profoundly enlarged Purkinje cell mitochondria, the presence of inter-neuronal cellular protrusions in the molecular layer, and signs of degeneration in the distal dendrites of the Purkinje cells. Since these morphologic signs are not apparent in the control animals, they are not likely to be due to caging or tissue processing effects. The particular nature of the structural alterations in the nodulus, most notably the formation of lamellar bodies and the presence of degeneration, further suggests that excitotoxicity (damaging overstimulation of neurons) may play a role in the short-term neural response to spaceflight. These findings suggest a structural basis for the neuronal and synaptic plasticity accompanying the central nervous system response to altered gravity and help identify the cellular bases underlying the vestibular abnormalities experienced by astronauts during periods of adaptation and re-adaptation to different gravitational forces. Also, since the short- and long-term changes in neural structure occurring during such periods of adaptation resemble the neuronal alterations that occur in some neurologic disorders such as stroke, these findings may offer guidance in the development of strategies for rehabilitation and treatment of such disorders.

Holstein, Gay R.↗
NASA NTRS1981

Applications of polymer extrusion technology to coal processing

Upon heating, many of the middle-aged bituminous coals exhibit a plasticity very similar to polyethylene for a few minutes. Plastic coal can be extruded, pelletized or molded using common plastics technology and equipment. Investigations concerning the plastic state of coals are conducted with the objective to develop techniques which will make useful commercial applications of this property possible. Experiments which show the characteristics of plastic-state coal are discussed, and problems related to a continuous extrusion of coal are considered. Probably the most significant difference between the continuous extrusion of coal and the extrusion of a thermoplastic polymer is that volatiles are continuously being released from the coal. Attention is given to aspects of dragflow, solids feeding, and melt pumping. Application potentials for plastic coal extrusion might be related to coal gasification, direct liquefaction, and coal combustion.

Lewis, D. W.↗
NASA NTRS1992

Mechanisms of fatigue crack retardation following single tensile overloads in powder metallurgy aluminum alloys

In ingot metallurgy (IM) alloys, the number of delay cycles following a single tensile overload typically increases from a minimum at an intermediate baseline stress intensity range, Delta-K(B), with decreasing Delta-K(B) approaching threshold and increasing Delta-K(B) approaching unstable fracture to produce a characteristic 'U' shaped curve. Two models have been proposed to explain this behavior. One model is based on the interaction between roughness and plasticity-induced closure, while the other model only utilizes plasticity-induced closure. This article examines these models, using experimental results from constant amplitude and single overload fatigue tests performed on two powder metallurgy (PM) aluminum alloys, AL-905XL and AA 8009. The results indicate that the 'U'-shaped curve is primarily due to plasticity-induced closure, and that the plasticity-induced retardation effect is through-thickness in nature, occurring in both the surface and interior regions. However, the retardation effect is greater at the surface, because the increase in plastic strain at the crack tip and overload plastic zone size are larger in the plane-stress surface regions than in the plane-strain interior regions. These results are not entirely consistent with either of the proposed models.

Bray, G. H.↗
NASA NTRS1982

Advanced Welding Tool

Accutron Tool & Instrument Co.'s welder was originally developed as a tool specifically for joining parts made of plastic or composite materials in any atmosphere to include the airless environment of space. Developers decided on induction or magnetic heating to avoid causing deformation and it also can be used with almost any type of thermoplastic material. Induction coil transfers magnetic flux through the plastic to a metal screen that is sandwiched between the sheets of plastic to be joined. When welder is energized, alternating current produces inductive heating on the screen causing the adjacent plastic surfaces to melt and flow into the mesh, creating a bond on the total surface area. Dave Brown, owner of Great Falls Canoe and Kayak Repair, Vienna, VA, uses a special repair technique based on operation of the Induction Toroid Welder to fix canoes. Whitewater canoeing poses the problem of frequent gashes that are difficult to repair. The main reason is that many canoes are made of plastics. The commercial Induction model is a self-contained, portable welding gun with a switch on the handle to regulate the temperature of the plastic melting screen. Welder has a broad range of applications in the automobile, appliance, aerospace and construction industries.

Source record↗
NASA NTRS2004

Compaction of Space Mission Wastes

The current solid waste management system employed on the International Space Station (ISS) consists of compaction, storage, and disposal. Wastes such plastic food packaging and trash are compacted manually and wrapped in duct tape footballs by the astronauts. Much of the waste is simply loaded either into the empty Russian Progress vehicle for destruction on reentry or into Shuttle for return to Earth. This manual method is wasteful of crew time and does not transition well to far term missions. Different wastes onboard spacecraft vary considerably in their characteristics and in the appropriate method of management. In advanced life support systems for far term missions, recovery of resources such as water from the wastes becomes important. However waste such as plastic food packaging, which constitutes a large fraction of solid waste (roughly 21% on ISS, more on long duration missions), contains minimal recoverable resource. The appropriate management of plastic waste is waste stabilization and volume minimization rather than resource recovery. This paper describes work that has begun at Ames Research Center on development of a heat melt compactor that can be used on near term and future missions, that can minimize crew interaction, and that can handle wastes with a significant plastic composition. The heat melt compactor takes advantage of the low melting point of plastics to compact plastic materials using a combination of heat and pressure. The US Navy has demonstrated successful development of a similar unit for shipboard application. Ames is building upon the basic approach demonstrated by the Navy to develop an advanced heat melt type compactor for space mission type wastes.

Fisher, John↗
NASA NTRSDate not supplied

Method Development for Experimental Characterization of Dynamic Strength of Aluminum Structures

Space Flight Hardware (SFH) experiences intense vibratory loading during flight, which only lasts a few minutes. When determining the appropriate size of these components to withstand such loading without becoming damaged (plastically deforming or breaking), standard design practice is to assume that the peak dynamic loads are applied statically. In doing so, the resulting stress is compared against a material strength parameter obtained from a quasi-static experiment. Since the near-peak stresses are only experienced over a small fraction of time in reality, this approach leads to design conservatism that unnecessarily increases structural mass as well as the associated inefficiency and financial cost. In an effort to modernize engineering design standards to appropriately consider the higher practical strength of dynamically loaded structures, this overarching research project seeks to develop an experimental test procedure for quantifying the dynamic strength of metallic alloys as a function of excitation frequency. In the ideal case, the characterization test would include an in-situ method for monitoring the onset and progression of plastic deformation of the test specimen undergoing vibratory loading. These new tests are designed to be high intensity (forcing amplitude), short term (60 seconds at full amplitude), and cyclic in nature (sinusoidal excitation via attached stinger to an otherwise cantilevered beam). In addition, the initial metallic alloy under investigation is 6061 aluminum, due to its wide use and applicability for SFH. Thus far, the most promising monitoring method under development with live-capacity is to track hysteresis behavior of the beam from power dissipation trends, calculated via force (from transducer on excitation stinger) and velocity (measurements from Laser Doppler Vibrometer) data and work to distinguish between elastic and plastic features. As a key component of this ongoing method development, any pseudo-live indication of plasticity can be corroborated against the outcome of a pre-post assessment of damage via macroscopic evaluation of beam geometry (i.e. assessing any permanent change in the beam’s tip deflection). Support for experimental design decisions as well as dynamic strength data from tests with excitation frequencies of 10, 40, and 55 Hz will be discussed. This work contributes to the foundation for a new type of vibration-based characterization experiments and generates initial data on the functional strength of 6061 aluminum under the conditions considered. Keywords: vibrations, plastic deformation, aluminum

vibrations↗
NASA NTRSDate not supplied

Experimental Calibration of Flow Rule Coefficients for LS-Dyna Mat_213

Composite materials have become a popular choice in aerospace engineering applications due to their low weight, high specific stiffness, high specific energy absorption, and economic synthesis. As use of composite materials has proliferated, the need for accurate simulation under extreme loading conditions is of increasing importance. *MAT_213 is a tabulated plasticity and damage material model in LS-DYNA designed for such use cases. To account for the nonlinear material response, a plasticity algorithm is used, which employs a non-associative flow rule with coefficients requiring experimental calibration. This work outlines an experimental methodology for calibrating these coefficients using the macroscopic stress-strain response and microscopic in-plane strain measurements from coupon scale experiments. The model material used for the development and demonstration of this methodology is a plain weave woven fabric with T300 carbon fiber tows in the warp direction and Kevlar© 49 fiber tows in the weft direction, and an Epon© 828/Epikure© 3223 thermoset epoxy matrix. Coupon-scale tensile testing performed at multiple fiber angles (carbon fibers oriented 0º, 22.5º, 45º, 67.5º, and 90º relative to the loading axis) provides data for multiple calibration processes. The measured plastic strain increments in the principal material coordinate are used to set limits for ratios between flow rule coefficients. The identified ranges are used to bound the search for a set of coefficients, leading to convergence of different coupon responses in the effective stress – effective plastic strain space. Flow rule coefficients found by this methodology are then used as (i) input for LS-DYNA simulations of uniaxial tension coupon tests at varying fiber angles, and (ii) comparison of predicted values for the plastic Poisson’s ratio in global coordinates with the experimentally measured one for all off-axis orientations. These results are quantitatively and qualitatively compared to macroscopic stress-strain curves and experimental strain components. The conformity of the experimentally measured quantities with those derived from the simulations provide a means for assessing the quality of calibrated coefficients.

Polymer Matrix Composites↗
NASA NTRS1972

An etiological study of phthalate self-contamination of spacecraft and contamination from their earthly environs

Phthalates are very objectionable contaminants in space experiments because of their strong absorption in the UV and IR regions of the spectrum. Thus, even minute amounts of these compounds migrating to optical equipment, in test or space flight conditions, can seriously compromise the results of experiments by altering the sensitivity of the functional equipment. Volatility data of the phthalates and other plasticizers are presented in addition to UV spectra of ultrathin films of these same types of compounds. Sources of plasticizer contamination are revealed with special recognition given to di-2-ethylhexyl phthalate (DEHP), the single most ubiquitous plasticizer in use. A surprisingly large percentage of the outgassing condensates from vacuum testing of spacecraft contain DEHP as well as other plasticizers. IR and gas chromatography/mass spectroscopy methods were used to analyze samples from spacecraft. Methods for successful reduction of plasticizers and other contaminants are mentioned.

Gross, F. C.↗
NASA NTRS1975

PLANS: A finite element program for nonlinear analysis of structures. Volume 1: Theoretical manual

The PLANS system is described which is a finite element program for nonlinear analysis. The system represents a collection of special purpose computer programs each associated with a distinct physical problem class. Modules of PLANS specifically referenced and described in detail include: (1) REVBY, for the plastic analysis of bodies of revolution; (2) OUT-OF-PLANE, for the plastic analysis of 3-D built-up structures where membrane effects are predominant; (3) BEND, for the plastic analysis of built-up structures where bending and membrane effects are significant; (4) HEX, for the 3-D elastic-plastic analysis of general solids; and (5) OUT-OF-PLANE-MG, for material and geometrically nonlinear analysis of built-up structures. The SATELLITE program for data debugging and plotting of input geometries is also described. The theoretical foundations upon which the analysis is based are presented. Discussed are the form of the governing equations, the methods of solution, plasticity theories available, a general system description and flow of the programs, and the elements available for use.

Pifko, A.↗
NASA NTRS1975

The Application of Strain Range Partitioning Method to Torsional Creep-Fatigue Interaction

The method of strain range partitioning was applied to a series of torsional fatigue tests conducted on tubular 304 stainless steel specimens at 1200 F. Creep strain was superimposed on cycling strain, and the resulting strain range was partitioned into four components; completely reversed plastic shear strain, plastic shear strain followed by creep strain, creep strain followed by plastic strain and completely reversed creep strain. Each strain component was related to the cyclic life of the material. The damaging effects of the individual strain components were expressed by a linear life fraction rule. The plastic shear strain component showed the least detrimental factor when compared to creep strain reversed by plastic strain. In the latter case, a reduction of torsional fatigue life in the order of magnitude of 1.5 was observed.

Zamrik, S. Y.↗