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With optical holography or ultrasonic equipment, process prepares standards for use in detection of flaws in bonded panels. Metal-to-metal, composite-to-metal, and composite-to-composite flaw standards have been produced by this process, and all have been used and tested successfully.
Technique monitors structural flaws in 105-in. diameter tanks. Tank surface is divided into many areas and each area is sectioned into 20 equilateral triangles that form icosahedron. Twelve transducers are equally positioned on tank surface at vertex of each triangle. Transducers monitor area for flaws by detecting any increase in acoustical activity.
Axial load fatigue and fracture tests were conducted on thick welded plates of 2219-T87 aluminum alloy to determine the tensile strength properties and the flaw growth behavior in electron beam, gas metal arc, and pulse current gas tungsten arc welds for plates 6.35 centimeters (2.5 in.) thick. The tests were conducted in room temperature air and in liquid nitrogen environments. Specimens were tested in both the as-welded and the aged after welding conditions. The experimental crack growth rate were correlated with theoretical crack growth rate predictions for semielliptical surface flaws.
An attempt is made to provide the necessary analytical tools for the application of two different types of fracture criteria to shell structures. Of particular interest is the problem of fracture propagation and arrest in a cylindrical pressure vessel containing an initial surface flaw. It is assumed that the flaw has the most unfavorable geometry and orientation, namely, it is a crack lying on a meridional plane. Stress intensity factor for a part-through crack, and a surface or internal crack with a fully yielded net ligament are considered. Attention is given to constant delta curves for depressurization studies and to depressurization and crack arrest in pressure vessels.
The effect of initial flaw shape and depth on the cycles required to produce a pressure leak condition in parent and welded 2219-T87 aluminum was examined for thicknesses from 0.04 to 0.3 inch. Initial flaw aspect ratios of 0.5, 0.3, and 0.15 were examined for tests conducted at a frequency of 4 Hz at room temperature and at 300 F. A computer program developed by Forman was used to predict the cycles to leak curve as a function of initial crack aspect ratio, material thickness, and specimen type and the results compared with the experimental data. Sources of error in the crack propagation analysis and the interface with NDI capabilities are discussed.
Six thicknesses of 2219-T87 aluminum base metal surface flaw and center crack specimens ranging from 9.53 to 0.635 mm (0.375 to 0.025 inch) were tested at temperatures ranging from 295K to 20K. Additionally, 6A1-4V STA titanium base metal specimens were tested in three thicknesses 3.18, 2.03, and 1.02 mm (0.125, 0.080 and 0.040 inch) at room temperature. All tests were conducted on uniaxial specimens. Results were analyzed and compared with previously developed data to establish a criterion for proof testing thin walled pressure vessels. The data analysis and exact flaw size dimensions are presented.
Static fracture tests were performed on surface flawed specimens of aluminum and titanium alloys. A simulated proof overload cycle was applied prior to all of the cyclic tests. Variables included in each test series were flaw shapes and thickness. Additionally, test temperature was a variable for the aluminum test series. The crack opening displacement and stress-strain data obtained are presented.
Laser-scanned photoacoustic spectroscopy has been used to detect tightly closed surface cracks in three structural ceramic materials: sintered silicon nitride, reaction-bonded silicon nitride, and sintered silicon carbide. It is found that the amplitude of the photoacoustic signal from the flaws is greater for the silicon nitrides than for silicon carbide, which is attributed to the lower thermal diffusivity of silicon nitride as well as differences in the grain size distribution and chemical composition. Signal amplitude, reproducibility, and signal-to-noise ratio are acceptable for effective flaw detection
Inherent flaws, as well as the effects of rate and time, are shown by tests on viscoelastic adhesive-bonded single lap joints to be as critical in joint failure as environmental and stress concentration effects, with random inherent flaws and loading rate changes resulting in an up to 40% reduction in joint strength. It is also found that the asymptotic creep stress, below which no delayed failure may occur, may under creep loading be as much as 45% less than maximum adhesive strength. Attention is given to test results for the case of titanium-LARC-3 adhesive single-lap specimens.
This paper reviews an experimental method for estimating both flaw shapes and stress intensity factors for complex three dimensional cracked body problems encountered in the sub-critical flaw growth regime prior to instability. Examples of the use of the method are cited, and the energy-density approach is suggested as a theory of sufficient generality to accommodate the complex behaviors observed.
Although the intrinsic strength of silicon dioxide glass is of the order of 10 to the 6th power lb/sq in, the practical strength is roughly two orders of magnitude below this theoretical limit, and depends almost entirely on the surface condition of the glass, that is, the number and size of flaws and the residual surface compression (temper) in the glass. Glass parts always fail in tension when these flaws grow under sustained loading to some critical size. Research associated with glass encapsulated crystalline-Si photovoltaic (PV) modules has greatly expanded our knowledge of glass breaking strength and developed sizeable data base for commercially available glass types. A detailed design algorithm is developed for thickness sizing of rectangular glass plates subject to pressure loads. Additional studies examine the strength of glass under impact loading conditions such as that caused by hail. Although the fundamentals of glass breakage are directly applicable to thin film modules, the fracture strength of typical numerical glass must be replaced with data that reflect the high temperature tin oxide processing, laser scribing, and edge processing peculiar to thin film modules. The fundamentals of glass breakage applicable to thin film modules and preliminary fracture strength data for a variety of 1 ft square glass specimens representing preprocessed and post processed sheets from current amorphous-Si module manufacturers are presented.
The capabilities were investigated of projection microfocus x-radiography, ultrasonic velocity and attenuation, and reflection scanning acoustic microscopy for characterizing silicon carbide specimens. Silicon carbide batches covered a range of densities and different microstructural characteristics. Room temperature, four point flexural strength tests were conducted. Fractography was used to identify types, sizes, and locations of fracture origins. Fracture toughness values were calculated from fracture strength and flaw characterization data. Detection capabilities of radiography and acoustic microscopy for fracture-causing flaws were evaluated. Applicability of ultrasonics for verifying material strength and toughness was examined.
This paper uses the Newman-Raju model, the Paris crack growth rate law, and a fixed R ratio to demonstrate the analytical considerations associated with predicting stress intensity distributions and fatigue crack growth of surface flaws under conditions of small-scale yielding. Problems which lie outside the realm of the model used in the analytical description are presented. It is concluded that, while the model employed provides remarkable predictive capability in a variety of surface flaw problems, many exceptional cases remain to be modeled.
The calculation of shape and scale parameters of the two-parameter Weibull distribution is described using the least-squares analysis and maximum likelihood methods for volume- and surface-flaw-induced fracture in ceramics with complete and censored samples. Detailed procedures are given for evaluating 90 percent confidence intervals for maximum likelihood estimates of shape and scale parameters, the unbiased estimates of the shape parameters, and the Weibull mean values and corresponding standard deviations. Furthermore, the necessary steps are described for detecting outliers and for calculating the Kolmogorov-Smirnov and the Anderson-Darling goodness-of-fit statistics and 90 percent confidence bands about the Weibull distribution. It also shows how to calculate the Batdorf flaw-density constants by uing the Weibull distribution statistical parameters. The techniques described were verified with several example problems, from the open literature, and were coded. The techniques described were verified with several example problems from the open literature, and were coded in the Structural Ceramics Analysis and Reliability Evaluation (SCARE) design program.
The effects of manufacture flaws and repairs in high altitude scientific balloons was examined. A right circular cylinder was used to induce a biaxial tension-tension stress field in the polyethlene film used to manufacture these balloons. A preliminary investigation of the effect that cylinder geometry has on stress rate as a function of inflation rate was conducted. The ultimate goal was to rank, by order of degrading effects, the flaws and repairs commonly found in current high altitude balloons.
To predict the fatigue life of machine parts which contain flaws in regions of stress concentration, the engineer needs to treat a series of crack sizes and/or shapes quickly and economically. In this paper the stress intensity factor distributions for circular surface flaws in the roots of fillets in rods loaded by remote tension are presented and examined. The examination reveals insight into the interaction of cracks with other stress concentrating discontinuities, and based on this it is suggested that weight function methods used in conjunction with known crack solutions may provide needed, efficient stress intensity factor prediction methods for such three-dimensional geometries.
The calculation of shape and scale parametes of the two-parameter Weibull distribution is described using the least-squares analysis and maximum likelihood methods for volume- and surface-flaw-induced fracture in ceramics with complete and censored samples. Detailed procedures are given for evaluating 90 percent confidence intervals for maximum likelihood estimates of shape and scale parameters, the unbiased estimates of the shape parameters, and the Weibull mean values and corresponding standard deviations. Furthermore, the necessary steps are described for detecting outliers and for calculating the Kolmogorov-Smirnov and the Anderson-Darling goodness-of-fit statistics and 90 percent confidence bands about the Weibull distribution. It also shows how to calculate the Batdorf flaw-density constants by using the Weibull distribution statistical parameters. The techniques described were verified with several example problems, from the open literature, and were coded in the Structural Ceramics Analysis and Reliability Evaluation (SCARE) design program.
This manual describes the operation and theory of the PC-CARES (Personal Computer-Ceramic Analysis and Reliability Evaluation of Structures) computer program for the IBM PC and compatibles running PC-DOS/MS-DOR OR IBM/MS-OS/2 (version 1.1 or higher) operating systems. The primary purpose of this code is to estimate Weibull material strength parameters, the Batdorf crack density coefficient, and other related statistical quantities. Included in the manual is the description of the calculation of shape and scale parameters of the two-parameter Weibull distribution using the least-squares analysis and maximum likelihood methods for volume- and surface-flaw-induced fracture in ceramics with complete and censored samples. The methods for detecting outliers and for calculating the Kolmogorov-Smirnov and the Anderson-Darling goodness-of-fit statistics and 90 percent confidence bands about the Weibull line, as well as the techniques for calculating the Batdorf flaw-density constants are also described.