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DOE OSTI2017

The Effects of Specimen Geometry on the Plastic Deformation of AA 2219-T8 Aluminum Alloy Under Dynamic Impact Loading

The effects of specimen geometry on shear strain localization in AA 2219-T8 aluminum alloy under dynamic impact loading were investigated. The alloy was machined into cylindrical, cuboidal and conical (frustum) test specimens. Both deformed and transformed adiabatic shear bands developed in the alloy during the impact loading. The critical strain rate for formation of the deformed band was determined to be 2500 s{sup −1} irrespective of the specimen geometry. The critical strain rate required for formation of transformed band is higher than 3000 s{sup −1} depending on the specimen geometry. The critical strain rate for formation of transformed bands is lowest (3000 s{sup −1}) in the Ø5 mm × 5 mm cylindrical specimens and highest (> 6000 s{sup −1}) in the conical specimens. The cylindrical specimens showed the greatest tendency to form transformed bands, whereas the conical specimen showed the least tendency. The shape of the shear bands on the impacted plane was also observed to be dependent on the specimen geometry. Whereas the shear bands on the compression plane of the conical specimens formed elongated cycles, two elliptical shaped shear bands facing each other were observed on the cylindrical specimens. Two parallel shear bands were observed on the compression planes of the cuboidal specimens. The dynamic stress–strain curves vary slightly with the specimen geometry. The cuboidal specimens exhibit higher tendency for strain hardening and higher maximum flow stress than the other specimens. The microstructure evolution leading to the formation of transformed bands is also discussed in this paper.

36 MATERIALS SCIENCE↗

NASA NTRS1991

The use of direct numerical simulation data in turbulence modeling

Direct numerical simulations (DNS) of turbulent flows provide a complete data base to develop and to test turbulence models. In this article, the progress made in developing models for the dissipation rate equation is reviewed. New scaling arguments for the various terms in the dissipation rate equation were tested using data from DNS of homogeneous shear flows. Modifications to the epsilon-equation model that take into account near-wall effects were developed using DNS of turbulent channel flows. Testing of new models for flows under mean compression was carried out using data from DNS of isotropically compressed turbulence. In all of these studies the data from the simulations was essential in guiding the model development. The next generation of DNS will be at higher Reynolds numbers, and will undoubtedly lead to improved models for computations of flows of practical interest.

Mansour, N. N.↗

NASA NTRS2006

Cold Flow Testing for Liquid Propellant Rocket Injector Scaling and Throttling

Scaling and throttling of combustion devices are important capabilities to demonstrate in development of liquid rocket engines for NASA's Space Exploration Mission. Scaling provides the ability to design new injectors and injection elements with predictable performance on the basis of test experience with existing injectors and elements, and could be a key aspect of future development programs. Throttling is the reduction of thrust with fixed designs and is a critical requirement in lunar and other planetary landing missions. A task in the Constellation University Institutes Program (CUIP) has been designed to evaluate spray characteristics when liquid propellant rocket engine injectors are scaled and throttled. The specific objectives of the present study are to characterize injection and primary atomization using cold flow simulations of the reacting sprays. These simulations can provide relevant information because the injection and primary atomization are believed to be the spray processes least affected by the propellant reaction. Cold flow studies also provide acceptable test conditions for a university environment. Three geometric scales - 1/4- scale, 1/2-scale, and full-scale - of two different injector element types - swirl coaxial and shear coaxial - will be designed, fabricated, and tested. A literature review is currently being conducted to revisit and compile the previous scaling documentation. Because it is simple to perform, throttling will also be examined in the present work by measuring primary atomization characteristics as the mass flow rate and pressure drop of the six injector element concepts are reduced, with corresponding changes in chamber backpressure. Simulants will include water and gaseous nitrogen, and an optically accessible chamber will be used for visual and laser-based diagnostics. The chamber will include curtain flow capability to repress recirculation, and additional gas injection to provide independent control of the backpressure. This paper provides a short review of the appropriate literature, as well as descriptions of plans for experimental hardware, test chamber instrumentation, diagnostics, and testing.

Kenny, Jeremy R.↗

DOE OSTI2015

Performance of internal covariance estimators for cosmic shear correlation functions

Data re-sampling methods such as the delete-one jackknife are a common tool for estimating the covariance of large scale structure probes. In this paper we investigate the concepts of internal covariance estimation in the context of cosmic shear two-point statistics. We demonstrate how to use log-normal simulations of the convergence field and the corresponding shear field to carry out realistic tests of internal covariance estimators and find that most estimators such as jackknife or sub-sample covariance can reach a satisfactory compromise between bias and variance of the estimated covariance. In a forecast for the complete, 5-year DES survey we show that internally estimated covariance matrices can provide a large fraction of the true uncertainties on cosmological parameters in a 2D cosmic shear analysis. The volume inside contours of constant likelihood in the $\Omega_m$-$\sigma_8$ plane as measured with internally estimated covariance matrices is on average $\gtrsim 85\%$ of the volume derived from the true covariance matrix. The uncertainty on the parameter combination $\Sigma_8 \sim \sigma_8 \Omega_m^{0.5}$ derived from internally estimated covariances is $\sim 90\%$ of the true uncertainty.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS2000

Design, Fabrication, and Testing of Ceramic Joints for High Temperature SiC/SiC Composites

Various issues associated with the design and mechanical evaluation of joints of ceramic matrix composites are discussed. The specific case of an affordable, robust ceramic joining technology (ARCJoinT) to join silicon carbide (CG-Nicalon(sup TM)) fiber-reinforced-chemically vapor infiltrated (CVI) silicon carbide matrix composites is addressed. Experimental results are presented for the time and temperature dependence of the shear strength of these joints in air up to 1200 C. From compression testing of double-notched joint specimens with a notch separation of 4 mm, it was found that the apparent shear strength of the joints decreased from 92 MPa at room temperature to 71 MPa at 1200 C. From shear stress-rupture testing in air at 1200 C it was found that the shear strength of the joints decreased rapidly with time from an initial shear strength of 71 to 17.5 MPa after 14.3 hr. The implications of these results in relation to the expected long-term service life of these joints in applications at elevated temperatures are discussed.

Singh, Mrityunjay↗

NASA NTRS2005

Method for Estimating Thread Strength Reduction of Damaged Parent Holes with Inserts

During normal assembly and disassembly of bolted-joint components, thread damage and/or deformation may occur. If threads are overloaded, thread damage/deformation can also be anticipated. Typical inspection techniques (e.g. using GO-NO GO gages) may not provide adequate visibility of the extent of thread damage. More detailed inspection techniques have provided actual pitch-diameter profiles of damaged-hardware holes. A method to predict the reduction in thread shear-out capacity of damaged threaded holes has been developed. This method was based on testing and analytical modeling. Test samples were machined to simulate damaged holes in the hardware of interest. Test samples containing pristine parent-holes were also manufactured from the same bar-stock material to provide baseline results for comparison purposes. After the particular parent-hole thread profile was machined into each sample a helical insert was installed into the threaded hole. These samples were tested in a specially designed fixture to determine the maximum load required to shear out the parent threads. It was determined from the pristine-hole samples that, for the specific material tested, each individual thread could resist an average load of 3980 pounds. The shear-out loads of the holes having modified pitch diameters were compared to the ultimate loads of the specimens with pristine holes. An equivalent number of missing helical coil threads was then determined based on the ratio of shear-out loads for each thread configuration. These data were compared with the results from a finite element model (FEM). The model gave insights into the ability of the thread loads to redistribute for both pristine and simulated damage configurations. In this case, it was determined that the overall potential reduction in thread load-carrying capability in the hardware of interest was equal to having up to three fewer threads in the hole that bolt threads could engage. One- half of this potential reduction was due to local pitch-diameter variations and the other half was due to overall pitch-diameter enlargement beyond Class 2 fit. This result was important in that the thread shear capacity for this particular hardware design was the limiting structural capability. The details of the method development, including the supporting testing, data reduction and analytical model results comparison will be discussed hereafter.

Johnson, David L.↗

NASA NTRS2004

Epoxy Adhesives for Stator Magnet Assembly in Stirling Radioisotope Generators (SRG)

As NASA seeks to fulfill its goals of exploration and understanding through missions planned to visit the moons of Saturn and beyond, a number of challenges arise from the idea of deep space flight. One of the first problems associated with deep space travel is electrical power production for systems on the spacecraft. Conventional methods such as solar power are not practical because efficiency decreases substantially as the craft moves away from the Sun. The criterion for power generation during deep space missions are very specific, the main points requiring high reliability, low mass, minimal vibration and a long lifespan. A Stirling generator, although fairly old in concept, is considered to be a potential solution for electrical power generation for deep space flight. A Stirling generator works on the same electromagnetic principles of a standard generator, using the linear motion of the alternator through the stationary stator which produces electric induction. The motion of the alternator, however, is produced by the heating and cooling dynamics of pressurized gases. Essentially heating one end and cooling another of a contained gas will cause a periodic expansion and compression of the gas from one side to the other, which a displacer translates into linear mechanical motion. NASA needs to confirm that the materials used in the generator will be able to withstand the rigors of space and the life expectancy of the mission. I am working on the verification of the epoxy adhesives used to bond magnets to the steel lamination stack to complete the stator; in terms of in-service performance and durability under various space environments. Understanding the proper curing conditions, high temperature properties, and degassing problems as well as production difficulties are crucial to the long term success of the generator. system and steel substrate used in the stator. To optimize the curing conditions of the epoxies, modulated differential scanning calorimetry analysis was done as a function of cure time and temperatures. Adhesion bond strength was tested at various temperatures with lap shear samples using Hiperco 50 substrate to ensure that the proper adhesive is being used. To try and solve the problem of bondline thickness, micro glass beads of 0.0017" in diameter were investigated to see if any other physical properties of the epoxy were affected. Efforts will be made to develop a standard, optimized, fabrication process/procedure of sub-scale magnet-stator assemblies for various adhesive performance evaluation studies under simulated generator conditions. Also, accelerated aging testing will be done in a pressurized canister with stator assembly samples for three years to verify if any degassing or thermal degradation of the epoxy occurs. The necessity of verifying the correct epoxy adhesive system for the stator magnet in the SRG is crucial because failure of the stator assembly would jeopardize the electrical system, and thereby the entire mission itself. My work involves specimen fabrications, testing, and data analyses of the epoxy adhesive system for the stator magnet in the SRG is crucial because failure of the stator assembly would jeopardize the electrical system, and thereby the entire mission itself.

Cater, George M.↗

DOE OSTI2020

Indirectly probing the structural change in ion-irradiated Zr-Based metallic glasses from small scale mechanical tests

Ion irradiation was applied to tailor the structural heterogeneities in Zr-based metallic glasses at room temperature. Experimental methods of X-ray diffraction, nanoindentation, and micropillar compression were conducted to examine the irradiation effects on their structural and mechanical property changes. It is found that the irradiated materials retained amorphous structure after room-temperature Ni ion irradiation. The reduction of elastic modulus and hardness measured by nanoindentation indicated the irradiation-induced mechanical degradation. A unified statistic model was employed to quantitatively predict the density and strength of irradiation defects, although their specific structural and physical nature is not explicitly included in this model. The transition of non-intersecting shear bands to multiple intersecting shear bands was observed on compression tests of irradiated micropillars with the increase of irradiation dose. Furthermore, the analysis of the displacement excursion of micropillar compression tests indicated a different deformation mode from the unirradiated state. These results from nanoindentation pop-in and micro-pillar compression tests suggested that irradiation eventually leads to a new state with different types and characteristics of structural heterogeneities from violent displacement cascades and non-equilibrium energy deposition/dissipation processes, which also proves ion irradiation as an effective method to tune the structure and mechanical properties of metallic glasses.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Ronchi shearing interferometry for wavefronts with circular symmetry

Ronchi testing of a focused electromagnetic wave has in the last few years been used extensively at X-ray free-electron laser (FEL) facilities to qualitatively evaluate the wavefront of the beam. It is a quick and straightforward test, is easy to interpret on the fly, and can be used to align phase plates that correct the focus of aberrated beams. In general, a single Ronchigram is not sufficient to gain complete quantitative knowledge of the wavefront. However the compound refractive lenses that are commonly used at X-ray FELs exhibit a strong circular symmetry in their aberration, and this can be exploited. Furthermore, a simple algorithm that uses a single recorded Ronchigram to recover the full wavefront of a nano-focused beam, assuming circular symmetry, is presented, and applied to experimental measurements at the Matter in Extreme Conditions instrument at the Linac Coherent Light Source.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1997

Advanced Transportation Systems, Alternate Propulsion Subsystem Concepts

An understanding of the basic flow of of the subject hybrid model has been gained through this series of testing. Changing injectors (axial vs. radial) and inhibiting the flow between the upstream plenum and the CP section changes the basic flow structure, as evidenced by streamline and velocity contour plots. Numerous shear layer structures were identified in the test configurations; these structures include both standing and traveling vortices which may affect combustion ion stability. Standing vortices may play a role in the heat addition process as the oxidizer enters the motor, while traveling vortices may be instability mechanisms in themselves. Finally, the flow visualization and LVD measurements give insight into determining the effects of flow induced shear layers.

Source record↗

NASA NTRS1984

Deformation measurements of composite multi-span beam shear specimens by Moire interferometry

Experimental analyses were performed for determination of in plane deformations and shear strains in unidirectional and quasi-isotropic graphite-epoxy beams. Forty-eight ply beams were subjected to 5 point and 3 point flexure. Whole field measurements were recorded at load levels from about 20% to more than 90% of failure loads. Contour maps of U and W displacement fields were obtained by moire interferometry, using reference gratings of 2400 lines/mm. Clearly defined fringes with fringe orders exceeding 1000 were obtained. Whole field contour maps of shear strains were obtained by a method developed for these tests. Various anomalous effects were detected in the displacement fields. Their analysis indicated excess shear strains in resin rich zones in regions of shear tractions; free edge shear strains in quasi-isotropic specimens in regions of normal stresses; and shear stresses associated with cyclic shear compliances of quasi-isotropic plies in regions of shear tractions. Their contributions could occur independently or in superposition. Qualitative analyses addressed questions of relaxation; influence of contact stress distribution; specimen failure; effect of specimen overhang; nonlinearity; and qualities of 5 and 3 point flexure tests.

Post, D.↗

NASA NTRS1984

Reel Down - A balloon borne winch system for stratospheric sounding from above

A balloon-borne winch system has been developed and flight tested which permits the repetitive lowering and hoisting of a stratospheric sampling payload for distances of up to 20 km from a float altitude of 35-40 km. This new approach to in situ stratospheric measurements permits multiple scans of various depths and velocities, closely spaced over a period of hours or days, thus dramatically increasing observational effectiveness. The motor driven winch permits control of ascent velocities from 0-9 m/s with energy derived from a large battery; for descent, the motors are used as generators, velocity is controlled over the same range, and the energy is dumped radiatively to space. The 1.75 mm diameter tether is of braided Kevlar construction with a nylon jacket; it exhibits a 2900 N break strength. Both the winch and the payload suspended by the tether are fully instrumented to evaluate potentially destructive system-induced dynamics and the effects of stratospheric wind shears. The system was successfully flight tested by lowering a 62 kg payload for a distance of 12 km from a float altitude of 38.5 km and hoisting it back up again, both at velocities ranging between 5-9 m/s. Observations indicated minimal system-induced dynamical effects, and no adverse effects due to the 8 m/s wind shear present during flight.

Hazen, N. L.↗

DOE OSTI2013

Sample Data from a Distributed Acoustic Sensing Experiment at Garner Valley, California

In September 2013, an experiment using Distributed Acoustic Sensing (DAS) was conducted at Garner Valley, a test site of the University of California Santa Barbara (Lancelle et al., 2014). This submission includes one 45 kN shear shaker (called "large shaker" on the basemap) test for three different measurement systems. The shaker swept from a rest, up to 10 Hz, and back down to a rest over 60 seconds. Lancelle, C., N. Lord, H. Wang, D. Fratta, R. Nigbor, A. Chalari, R. Karaulanov, J. Baldwin, and E. Castongia (2014), Directivity and Sensitivity of Fiber-Optic Cable Measuring Ground Motion using a Distributed Acoustic Sensing Array (abstract # NS31C-3935), AGU Fall Meeting. https://agu.confex.com/agu/fm14/webprogram/Paper19828.html The e-poster is available at: https://agu.confex.com/data/handout/agu/fm14/Paper_19828_handout_696_0.pdf

15 GEOTHERMAL ENERGY↗

DOE OSTI2019

Effect of Boron Addition on Creep Strain during Impression Creep of P91 Steel

In an attempt to understand the effect of boron addition on creep deformation behavior under high stress and high temperature in martensitic P91 steel, impression creep tests were carried out on boron-free P91 (P91) and boron-added P91 (P91B) steels. The experimental program consisted of three steps, i.e., characterization of as-received steels by microhardness, optical microscopy (OM), transmission electron microscopy (TEM), electron backscattered diffraction (EBSD) and wavelength-dispersive spectroscopy (WDS); impression creep tests at 445 MPa and 625 °C on as-received steels; characterization at deformed plastic zones of impression-crept specimens by microhardness, OM, EBSD, TEM and WDS. Impression creep tests were run till a depth of penetration of 1.8 mm was achieved for both cases which ensured a sufficient plastic zone underneath indenter for subsequent microstructural investigations. Coarsening of M{sub 23}C{sub 6} carbides was observed in P91 steel during high-temperature creep loading, which leads to extensive strain hardening in deformed plastic region, resulting in impaired creep performance. On the contrary, dynamic recrystallization in P91B steel results in formation of small strain-free grains during creep loading which are responsible for increased resistance of the material to shear stresses during an impression creep test.

36 MATERIALS SCIENCE↗

DOE OSTI2020

EGS Collab Experiment 1: SIMFIP Notch-164 GRL Paper

Characterizing the stimulation mode of a fracture is critical to assess the hydraulic efficiency and the seismic risk related to deep fluid manipulations. We have monitored the three-dimensional displacements of a fluid-driven fracture during water injections in a borehole at ~1.5 km depth in the crystalline rock of the Sanford Underground Research Facility (USA). The fracture initiates at 61% of the minimum horizontal stress by micro-shearing of the borehole on a foliation plane. As the fluid pressure increases further, borehole axial and radial displacements increase with injection time highlighting the opening and sliding of a new hydrofracture growing ~10 m away from the borehole, in accordance with the ambient normal stress regime and in alignment with the microseismicity. Our study reveals how fluid-driven fracture stimulation can be facilitated by a mixed-mode process controlled by the complex hydromechanical evolution of the growing fracture. The data presented in this submission refer to the SIMFIP measurements and analyses of the stimulation tests conducted on the 164 ft (50 m) notch of the Sanford Underground Research Facility (SURF), during the EGS-Collab test 1. In addition to the datafiles, there is the draft of a manuscript submitted to Geophysical Research Letters (GRL).

15 GEOTHERMAL ENERGY↗

NASA NTRS1989

Composite fracture using the normal stress ratio theory

Experiments were performed on center-notched specimens of unidirectional AS4/3501-6 graphite-epoxy subjected to varied far-field loading conditions. Specimens tested include on-axis and off-axis tensile coupons and Iosipescu shear specimens, allowing the study of normal, shear, and combined far-field loading conditions. From the tests, the direction of initial crack extension and the far-field stresses at crack initiation and fracture are obtained. The normal stress ratio theory is subsequently applied within a macroscopic-level homogeneous anisotropic stress solution to predict the direction of crack extension, critical stresses, and other crack growth behavior for the experiments. Comparison between experimental results and theoretical predictions indicates that application of the normal stress ratio theory within a macroscopic-level stress analysis has significant potential as an approach to modeling composite crack growth.

Beuth, J. L., Jr.↗

NASA NTRS2003

Flaw Tolerance in Lap Shear Brazed Joints

Furnace brazing is a joining process used in the aerospace and other industries to produce strong permanent and hermetic structural joints. As in any joining process, brazed joints have various imperfections and defects. At the present time, our understanding of the influence of the internal defects on the strength of the brazed joints is not adequate. The goal of this 3-part investigation is to better understand the properties and failure mechanisms of the brazed joints containing defects. This study focuses on the behavior of the brazed lap shear joints because of their importance in manufacturing aerospace structures. In Part 1, an average shear strength capability and failure modes of the single lap joints are explored. Stainless steel specimens brazed with pure silver are tested in accordance with the AWS C3.2 standard. Comparison of the failure loads and the ultimate shear strength with the Finite Element Analysis (FEA) of the same specimens as a function of the overlap widths shows excellent correlation between the experimental and calculated values for the defect-free lap joints. A damage zone criterion is shown to work quite well in understanding the failure of the braze joints. In Part 2, the findings of the Part 1 will be verified on the larger test specimens. Also, various flaws will be introduced in the test specimens to simulate lack of braze coverage in the lap joints. Mechanical testing and FEA will be performed on these joints to verify that behavior of the flawed ductile lap joints is similar to joints with a reduced braze area. Finally, in Part 3, the results obtained in Parts 1 and 2 will be applied to the actual brazed structure to evaluate the load-carrying capability of a structural lap joint containing discontinuities. In addition, a simplified engineering procedure will be offered for the laboratory testing of the lap shear specimens.

Flom, Yury↗

NASA NTRS1983

Power turbine dynamics - An evaluation of a shear-mounted elastomeric damper

As an alternative to the more conventional squeeze-film bearing damper designs, a Viton-70 shear-mounted, elastomeric damper was built and tested in a T-55 power turbine high-speed balancing rig. This application demonstrated, for the first time, the feasibility of using elastomers as the primary rotor damping source in production turbine engine hardware. The shear-mounted damper design was selected because of its compatibility with actual gas turbine engine radial space constraints, its accommodation of both the radial and axial thrust loads present in gas turbine engines, and its capability of controlled axial preload. Test results showed that the Viton-70 elastomeric damper operated successfully and provided excellent control of both synchronous and nonsynchronous vibrations through all phases of testing to the maximum rotor speed of 1676 rad/s (16,000 rpm). Excellent correlation between the predicted and experienced critical speeds, mode shapes, and log decrements for the power turbine rotor and elastomer damper assembly was also achieved.

Zorzi, E. S.↗