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At least 91 records · Page 5

All sources NASA NTRS DOE OSTI

NASA NTRS1997

A. Palmgren Revisited: A Basis for Bearing Life Prediction

Bearing technology, as well as the bearing industry, began to develop with the invention of the bicycle in the 1850's. At the same time, high-quality steel was made possible by the Bessemer process. In 1881, H. Hertz published his contact stress analysis. By 1902, R. Stribeck had published his work based on Hertz theory to calculate the maximum load of a radially loaded ball bearing. By 1920, all of the rolling bearing types used today were being manufactured. AISI 52100 bearing steel became the material of choice for these bearings. Beginning in 1918, engineers directed their attention to predicting the lives of these bearings. In 1924, A. Palmgren published a paper outlining his approach to bearing life prediction. This paper was the basis for the Lundberg-Palmgren life theory published in 1947. A critical review of the 1924 Palmgren paper is presented here together with a discussion of its effect on bearing life prediction.

Zaretsky, Erwin V.↗

NASA NTRS1975

Life prediction of thermal-mechanical fatigue using strain-range partitioning

The applicability is described of the method of Strainrange Partitioning to the life prediction of thermal-mechanical strain-cycling fatigue. An in-phase test on 316 stainless steel is analyzed as an illustrative example. The observed life is in excellent agreement with the life predicted by the method using the recently proposed Step-Stress Method of experimental partitioning, the Interation Damage Rule, and the life relationships determined at an isothermal temperature of 705 C. Implications of the study are discussed relative to the general thermal fatigue problem.

Halford, G. R.↗

NASA NTRS1987

Life prediction and constitutive models for engine hot section anisotropic materials

The results are presented of a program designed to develop life prediction and constitutive models for two coated single crystal alloys used in gas turbine airfoils. The two alloys are PWA 1480 and Alloy 185. The two oxidation resistant coatings are PWA 273, an aluminide coating, and PWA 286, an overlay NiCoCrAlY coating. To obtain constitutive and fatigue data, tests were conducted on uncoated and coated specimens loaded in the CH76 100 CH110 , CH76 110 CH110 , CH76 111 CH110 and CH76 123 CH110 crystallographic directions. Two constitutive models are being developed and evaluated for the single crystal materials: a micromechanic model based on crystallographic slip systems, and a macroscopic model which employs anisotropic tensors to model inelastic deformation anisotropy. Based on tests conducted on the overlay coating material, constitutive models for coatings also appear feasible and two initial models were selected. A life prediction approach was proposed for coated single crystal materials, including crack initiation either in the coating or in the substrate. The coating initiated failures dominated in the tests at load levels typical of gas turbine operation. Coating life was related to coating stress/strain history which was determined from specimen data using the constitutive models.

Swanson, G. A.↗

NASA NTRS1995

Life prediction of aging aircraft wiring systems

The program goal is to develop a computerized life prediction model capable of identifying present aging progress and predicting end of life for aircraft wiring. A summary is given in viewgraph format of progress made on phase 1 objectives, which were to identify critical aircraft wiring problems; relate most common failures identified to the wire mechanism causing the failure; assess wiring requirments, materials, and stress environment for fighter aircraft; and demonstrate the feasibility of a time-temperature-environment model.

Slenski, George↗

NASA NTRS2001

Life Prediction Issues in Thermal/Environmental Barrier Coatings in Ceramic Matrix Composites

Issues and design requirements for the environmental barrier coating (EBC)/thermal barrier coating (TBC) life that are general and those specific to the NASA Ultra-Efficient Engine Technology (UEET) development program have been described. The current state and trend of the research, methods in vogue related to the failure analysis, and long-term behavior and life prediction of EBCITBC systems are reported. Also, the perceived failure mechanisms, variables, and related uncertainties governing the EBCITBC system life are summarized. A combined heat transfer and structural analysis approach based on the oxidation kinetics using the Arrhenius theory is proposed to develop a life prediction model for the EBC/TBC systems. Stochastic process-based reliability approach that includes the physical variables such as gas pressure, temperature, velocity, moisture content, crack density, oxygen content, etc., is suggested. Benefits of the reliability-based approach are also discussed in the report.

Shah, Ashwin R.↗

NASA NTRS1973

Life prediction of turbine components: On-going studies at the NASA Lewis Research Center

An overview is presented of the many studies at NASA-Lewis that form the turbine component life prediction program. This program has three phases: (1) development of life prediction methods for major failure modes through materials studies, (2) evaluation and improvement of these methods through a variety of burner rig studies on simulated components in research engines and advanced rigs. These three phases form a cooperative, interdisciplinary program. A bibliography of Lewis publications on fatigue, oxidation and coatings, and turbine engine alloys is included.

Spera, D. A.↗

DOE OSTI2025

Systematic feature design for cycle life prediction of lithium-ion batteries during formation

Optimization of the formation step in lithium-ion battery manufacturing is challenging due to limited physical understanding of solid-electrolyte interphase formation and the long testing time (∼100 days) for cells to reach the end of life. We propose a systematic feature-design framework that requires minimal domain knowledge for accurate cycle life prediction during formation. By only using two simple Q (V) features designed from our framework, extracted from formation data without any additional diagnostic cycles, we achieved an average of 9.87% error for cycle life prediction. Here, the physics-based investigation guided by the two designed features shows that the voltage ranges identified by our framework capture the effects of formation temperature and microscopic-particle resistance heterogeneity. By designing highly predictive, robust, and interpretable features, our approach can accelerate industrial battery formation research, leveraging the interplay between data-driven feature design and mechanistic understanding.

25 ENERGY STORAGE↗

NASA NTRS2000

Effect of Roller Profile on Cylindrical Roller Bearing Life Prediction

Four roller profiles used in cylindrical roller bearing design and manufacture were analyzed using both a closed form solution and finite element analysis (FEA) for stress and life. The roller profiles analyzed were flat, tapered end, aerospace, and fully crowned loaded against a flat raceway. Four rolling-element bearing life models were chosen for this analysis and compared. These were those of Weibull, Lundberg and Palmgren, Ioannides and Harris, and Zaretsky. The flat roller profile without edge loading has the longest predicted life. However, edge loading can reduce life by as much as 98 percent. The end tapered profile produced the highest lives but not significantly different than the aerospace profile. The fully crowned profile produces the lowest lives. The resultant predicted life at each stress condition not only depends on the life equation used but also on the Weibull slope assumed. For Weibull slopes of 1.5 and 2, both Lundberg-Palmgren and Iaonnides-Harris equations predict lower lives than the ANSI/ABMAJISO standards. Based upon the Hertz stresses for line contact, the accepted load-life exponent of 10/3 results in a maximum Hertz stress-life exponent equal to 6.6. This value is inconsistent with that experienced in the field.

Poplawski, Joseph V.↗

NASA NTRS1985

Thermal barrier coating life prediction model development

The objective is to develop an integrated life prediction model accounting for all potential life-limiting thermal barrier coating (TBC) degradation and failure modes, including spallation resulting from cyclic thermal stress, oxidation degradation, hot corrosion, erosion and foreign object damage.

Demasi, J. T.↗

NASA NTRS1990

A life prediction model for laminated composite structural components

A life prediction methodology for laminated continuous fiber composites subjected to fatigue loading conditions was developed. A summary is presented of research completed. A phenomenological damage evolution law was formulated for matrix cracking which is independent of stacking sequence. Mechanistic and physical support was developed for the phenomenological evolution law proposed above. The damage evolution law proposed above was implemented to a finite element computer program. And preliminary predictions were obtained for a structural component undergoing fatigue loading induced damage.

Allen, David H.↗

NASA NTRS1982

Creep-fatigue life prediction for engine hot section materials (isotropic)

The objectives of this program are the investigation of fundamental approaches to high temperature crack initiation life prediction, identification of specific modeling strategies and the development of specific models for component relevant loading conditions. A survey of the hot section material/coating systems used throughout the gas turbine industry is included. Two material/coating systems will be identified for the program. The material/coating system designated as the base system shall be used throughout Tasks 1-12. The alternate material/coating system will be used only in Task 12 for further evaluation of the models developed on the base material. In Task II, candidate life prediction approaches will be screened based on a set of criteria that includes experience of the approaches within the literature, correlation with isothermal data generated on the base material, and judgements relative to the applicability of the approach for the complex cycles to be considered in the option program. The two most promising approaches will be identified. Task 3 further evaluates the best approach using additional base material fatigue testing including verification tests. Task 4 consists of technical, schedular, financial and all other reporting requirements in accordance with the Reports of Work clause.

Moreno, V.↗

NASA NTRS1984

Thermal barrier coating life prediction model development

The objective of this program is to develop an integrated life prediction model accounting for all potential life-limiting Thermal Barrier Coating (TBC) degradation and failure modes including spallation resulting from cyclic thermal stress, oxidative degradation, hot corrosion, erosion, and foreign object damage (FOD). The mechanisms and relative importance of the various degradation and failure modes will be determined, and the methodology to predict predominant mode failure life in turbine airfoil application will be developed and verified. An empirically based correlative model relating coating life to parametrically expressed driving forces such as temperature and stress will be employed. The two-layer TBC system being investigated, designated PWA264, currently is in commercial aircraft revenue service. It consists of an inner low pressure chamber plasma-sprayed NiCoCrAlY metallic bond coat underlayer (4 to 6 mils) and an outer air plasma-sprayed 7 w/o Y2O3-ZrO2 (8 to 12 mils) ceramic top layer.

Demasi, J.↗

NASA NTRS1988

Fatigue life prediction modeling for turbine hot section materials

A major objective of the fatigue and fracture efforts under the Hot Section Technology (HOST) program was to significantly improve the analytic life prediction tools used by the aeronautical gas turbine engine industry. This was achieved in the areas of high-temperature thermal and mechanical fatigue of bare and coated high-temperature superalloys. The cyclic crack initiation and propagation resistance of nominally isotropic polycrystalline and highly anisotropic single crystal alloys were addressed. Life prediction modeling efforts were devoted to creep-fatigue interaction, oxidation, coatings interactions, multiaxiality of stress-strain states, mean stress effects, cumulative damage, and thermomechanical fatigue. The fatigue crack initiation life models developed to date include the Cyclic Damage Accumulation (CDA) and the Total Strain Version of Strainrange Partitioning (TS-SRP) for nominally isotropic materials, and the Tensile Hysteretic Energy Model for anisotropic superalloys. A fatigue model is being developed based upon the concepts of Path-Independent Integrals (PII) for describing cyclic crack growth under complex nonlinear response at the crack tip due to thermomechanical loading conditions. A micromechanistic oxidation crack extension model was derived. The models are described and discussed.

Halford, G. R.↗

NASA NTRS1989

Fatigue life prediction modeling for turbine hot section materials

A major objective of the fatigue and fracture efforts under the NASA Hot Section Technology (HOST) program was to significantly improve the analytic life prediction tools used by the aeronautical gas turbine engine industry. This was achieved in the areas of high-temperature thermal and mechanical fatigue of bare and coated high-temperature superalloys. The cyclic crack initiation and propagation resistance of nominally isotropic polycrystalline and highly anisotropic single crystal alloys were addressed. Life prediction modeling efforts were devoted to creep-fatigue interaction, oxidation, coatings interactions, multiaxiality of stress-strain states, mean stress effects, cumulative damage, and thermomechanical fatigue. The fatigue crack initiation life models developed to date include the Cyclic Damage Accumulation (CDA) and the Total Strain Version of Strainrange Partitioning (TS-SRP) for nominally isotropic materials, and the Tensile Hysteretic Energy Model for anisotropic superalloys. A fatigue model is being developed based upon the concepts of Path-Independent Integrals (PII) for describing cyclic crack growth under complex nonlinear response at the crack tip due to thermomechanical loading conditions. A micromechanistic oxidation crack extension model was derived. The models are described and discussed.

G R Halford↗

NASA NTRS2002

Structural Life and Reliability Metrics: Benchmarking and Verification of Probabilistic Life Prediction Codes

Over the past two decades there has been considerable effort by NASA Glenn and others to develop probabilistic codes to predict with reasonable engineering certainty the life and reliability of critical components in rotating machinery and, more specifically, in the rotating sections of airbreathing and rocket engines. These codes have, to a very limited extent, been verified with relatively small bench rig type specimens under uniaxial loading. Because of the small and very narrow database the acceptance of these codes within the aerospace community has been limited. An alternate approach to generating statistically significant data under complex loading and environments simulating aircraft and rocket engine conditions is to obtain, catalog and statistically analyze actual field data. End users of the engines, such as commercial airlines and the military, record and store operational and maintenance information. This presentation describes a cooperative program between the NASA GRC, United Airlines, USAF Wright Laboratory, U.S. Army Research Laboratory and Australian Aeronautical & Maritime Research Laboratory to obtain and analyze these airline data for selected components such as blades, disks and combustors. These airline data will be used to benchmark and compare existing life prediction codes.

Litt, Jonathan S.↗

NASA NTRS1992

A creep cavity growth model for creep-fatigue life prediction of a unidirectional W/Cu composite

A microstructural model was developed to predict creep-fatigue life in a (0)(sub 4), 9 volume percent tungsten fiber-reinforced copper matrix composite at the temperature of 833 K. The mechanism of failure of the composite is assumed to be governed by the growth of quasi-equilibrium cavities in the copper matrix of the composite, based on the microscopically observed failure mechanisms. The methodology uses a cavity growth model developed for prediction of creep fracture. Instantaneous values of strain rate and stress in the copper matrix during fatigue cycles were calculated and incorporated in the model to predict cyclic life. The stress in the copper matrix was determined by use of a simple two-bar model for the fiber and matrix during cyclic loading. The model successfully predicted the composite creep-fatigue life under tension-tension cyclic loading through the use of this instantaneous matrix stress level. Inclusion of additional mechanisms such as cavity nucleation, grain boundary sliding, and the effect of fibers on matrix-stress level would result in more generalized predictions of creep-fatigue life.

Kim, Young-Suk↗

NASA NTRS1985

Creep fatigue life prediction for engine hot section materials (isotropic)

The first two years of a two-phase program aimed at improving the high temperature crack initiation life prediction technology for gas turbine hot section components are discussed. In Phase 1 (baseline) effort, low cycle fatigue (LCF) models, using a data base generated for a cast nickel base gas turbine hot section alloy (B1900+Hf), were evaluated for their ability to predict the crack initiation life for relevant creep-fatigue loading conditions and to define data required for determination of model constants. The variables included strain range and rate, mean strain, strain hold times and temperature. None of the models predicted all of the life trends within reasonable data requirements. A Cycle Damage Accumulation (CDA) was therefore developed which follows an exhaustion of material ductility approach. Material ductility is estimated based on observed similarities of deformation structure between fatigue, tensile and creep tests. The cycle damage function is based on total strain range, maximum stress and stress amplitude and includes both time independent and time dependent components. The CDA model accurately predicts all of the trends in creep-fatigue life with loading conditions. In addition, all of the CDA model constants are determinable from rapid cycle, fully reversed fatigue tests and monotonic tensile and/or creep data.

Moreno, Vito↗

NASA NTRS1983

High-temperature fatigue in metals - A brief review of life prediction methods developed at the Lewis Research Center of NASA

The presentation focuses primarily on the progress we at NASA Lewis Research Center have made. The understanding of the phenomenological processes of high temperature fatigue of metals for the purpose of calculating lives of turbine engine hot section components is discussed. Improved understanding resulted in the development of accurate and physically correct life prediction methods such as Strain-Range partitioning for calculating creep fatigue interactions and the Double Linear Damage Rule for predicting potentially severe interactions between high and low cycle fatigue. Examples of other life prediction methods are also discussed. Previously announced in STAR as A83-12159

Halford, G. R.↗