Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “low cycle fatigue loading”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Failure Analysis of T-38 Aircraft Burst Hydraulic Aileron Return Line

During maintenance troubleshooting for fluctuating hydraulic pressures, a technician found that a right hand aileron return line, on the flight hydraulic side, was ruptured (Fig. 1, 2). This tubing is part of the Hydraulic Flight Control Aileron Return Reducer to Aileron Manifold and is suspected to be original to the T-38 Talon trainer aircraft. Ailerons are small hinged sections on the outboard portion of a wing used to generate rolling motion thereby banking the aircraft. The ailerons work by changing the effective shape of the airfoil of the outer portion of the wing [1]. The drawing, Northrop P/N 3-43033-55 (6/1960), specifies that the line is made from 0.375 inch OD, aluminum 5052-0 tubing with a 0.049 inch wall thickness. WW-T-787 requires the tube shall be seamless and uniform in quality and temper [2]. The test pressure for this line is 3000 psi, and the operational pressure for this line is estimated to be between 45 psi and 1500 psi based on dynamic loading during flight. Examination of the fracture surface found evidence of arrest bands originating on the inner diameter (Fig 3). Ductile dimples are observed on the tube fractures (Fig. 4). The etched cross-section revealed thinning and work-hardening in the burst region (Fig. 5). The wall thickness just outside the work-hardened fracture region measured 0.035". Barlow's Formula: P = 2St/D, where P is burst pressure, S is allowable stress, t is wall thickness and D is the outer diameter of tube. Using the ultimate tensile strength of 28 ksi and a measured wall thickness of 0.035 inches at burst, P = 5.2 ksi (burst pressure). Using the yield of 13 ksi (YS) for aluminum 5052-0, plastic deformation will happen at P = 2.4 ksi suggesting plastic deformation occurred at a proof pressure of 3.0 ksi. Conclusion: The burst resulted from high stress, low-cycle fatigue. Evidence of arrest bands originating on the inner diameter. Fracture is predominately shear dimples, characteristic of high load ductile fractures (Fig 6). Section wall reduction in the burst region. Plastic deformation and thinning of the out-of-specification tube wall likely happened during the initial proof testing years ago. Metallography of tubing away from rupture site confirmed tubing was seamless. Based on the tube microstructure, it is likely that the initial wall thickness was about 30 % thinner than the requirement of 0.049 inches. Fracture initiated on the ID and progressed to the OD (shear lip). The tube is made of the correct material of 5052-0 aluminum as verified using Optical Emission Spectroscopy (Table 2). The tubing hardness tested 77 HV100 (77 HRE). This hardness is slightly above the requirement for 70 HRE maximum for aluminum 5052-0 in AMS 2658C [3].

Martinez, J. E.↗
NASA NTRS1974

Cyclic fatigue analysis of rocket thrust chambers. Volume 1: OFHC copper chamber low cycle fatigue

A three-dimensional finite element elasto-plastic strain analysis was performed for the throat section of a regeneratively cooled rocket combustion chamber. The analysis employed the RETSCP finite element computer program. The analysis included thermal and pressure loads, and the effects of temperature dependent material properties, to determine the strain range corresponding to the chamber operating cycle. The analysis was performed for chamber configuration and operating conditions corresponding to a hydrogen-oxygen combustion chamber which was fatigue tested to failure. The computed strain range at typical chamber operating conditions was used in conjunction with oxygen-free, high-conductivity (OHFC) copper isothermal fatigue test data to predict chamber low-cycle fatigue life.

Miller, R. W.↗
NASA NTRS1975

High-Temperature, Low-Cycle Fatigue of Copper-Base Alloys for Rocket Nozzles. Part 1: Data Summary for Materials Tested in Prior Programs

A more detailed analysis of the results obtained in 188 previously reported low-cycle fatigue tests of various candidate materials for regeneratively-cooled, reusable rocket nozzle liners was reported. Plots of load range versus cycles were reported for each test along with a stress-strain hysteresis loop near half-life. In addition, a summary table was provided to compare N5 (cycles to a five percent load range drop) and Nf (cycles to complete specimen separation) values for each test.

Conway, J. B.↗
NASA NTRS1972

Fatigue Tests with Random Flight Simulation Loading

Crack propagation was studied in a full-scale wing structure under different simulated flight conditions. Omission of low-amplitude gust cycles had a small effect on the crack rate. Truncation of the infrequently occurring high-amplitude gust cycles to a lower level had a noticeably accelerating effect on crack growth. The application of fail-safe load (100 percent limit load) effectively stopped subsequent crack growth under resumed flight-simulation loading. In another flight-simulation test series on sheet specimens, the variables studied are the design stress level and the cyclic frequency of the random gust loading. Inflight mean stresses vary from 5.5 to 10.0 kg/sq mm. The effect of the stress level is larger for the 2024 alloy than for the 7075 alloy. Three frequencies were employed: namely, 10 cps, 1 cps, and 0.1 cps. The frequency effect was small. The advantages and limitations of flight-simulation tests are compared with those of alternative test procedures such as constant-amplitude tests, program tests, and random-load tests. Various testing purposes are considered. The variables of flight-simulation tests are listed and their effects are discussed. A proposal is made for performing systematic flight-simulation tests in such a way that the compiled data may be used as a source of reference.

Schijve, J.↗
DOE OSTI2022

Uncovering the role of nanoscale precipitates on martensitic transformation and superelasticity

Here we characterize the role of coherent nanoscale B2 Ni 50 Al 50 precipitates on the temperature- and stress-induced martensitic phase transformation in nanocrystalline Ni 63 Al 37 shape memory alloys using multi-million-atoms molecular dynamics (MD) simulations. We studied two types of precipitates: one with single crystal precipitates (SXP) and a second where grain boundaries cut through precipitates (PXP). Simulations reveal that the presence of B2 precipitates stabilizes the cyclic flag-shaped stress-strain response, characteristic of superelasticity, and reduces remnant strain. In contrast, single-phase nanocrystalline Ni 63 Al 37 exhibits degradation of the reverse transformation during cyclic loading and, eventually, incomplete reversible transformation within a few cycles. This is consistent with previous experimental findings of ultra-low fatigue in Ni-Ti-Cu alloys with Ti 2 Cu precipitates. The simulations reveal that the presence of precipitates significantly improves the reversibility of the transformation by acting as elastic zones that partially shield the martensitic transformation and drive the reverse transformation. A detailed analysis of the MD trajectories reveals that the martensitic transformation of the matrix induces ultra-large elastic deformation in some of the B2 precipitates (approximately 12%) to the point of resulting in a martensite-like atomic structure.

36 MATERIALS SCIENCE↗
NASA NTRS1977

Treatment of low strains and long hold times in high temperature metal fatigue by strainrange partitioning

A procedure for treating creep-fatigue for low strainranges and long hold times is outlined. A semi-experimental approach, wherein several cycles of the imposed loading is actually applied to a specimen in order to determine the stable hysteresis loop, can be very useful in the analysis. Because such tests require only a small fraction of the total failure time, they are not inherently prohibitive if experimental equipment is available. The need for accurate constitutive equations is bypassed because the material itself acts to translate the imposed loading into the responsive hysteresis loops. When strainrange partitioning has been applied in such cases very good results have been obtained.

Manson, S. S.↗
NASA NTRS1994

Isothermal Damage and Fatigue Behavior of SCS-6/Timetal 21S [0/90](Sub S) Composite at 650 Deg C

The isothermal fatigue damage and life behaviors of SCS-6/Timetal 21S (0/90)s were investigated at 650 C. Strain ratcheting and degradation of the composite's static elastic modulus were carefully monitored as functions of cycles to indicate damage progression. Extensive fractographic and metallographic analyses were conducted to determine damage/failure mechanisms. Resulting fatigue lives show considerable reductions in comparison to (0) reinforced titanium matrix composites subjected to comparable conditions. Notable stiffness degradations were found to occur after the first cycle of loading, even at relatively low maximum stress levels, where cyclic lives are greater than 25,000 cycles. This was attributed to the extremely weak fiber/matrix bond which fails under relatively low transverse loads. Stiffness degradations incurred on first cycle loadings and degradations thereafter were found to increase with increasing maximum stress. Environmental effects associated with oxidation of the (90) fiber interfaces clearly played a role in the damage mechanisms as fracture surfaces revealed environment assisted matrix cracking along the (90) fibers. Metallographic analysis indicated that all observable matrix fatigue cracks initiated at the (90) fiber/matrix interfaces. Global de-bonding in the loading direction was found along the (90) fibers. No surface initiated cracks were evident and minimal if any (0) fiber cracking was visible.

Castelli, Michael G.↗
NASA NTRS2006

Unsteady Flow Simulation of High-speed Turbopumps

Computation of high-speed hydrodynamics requires high-fidelity simulation to resolve flow features involving transient flow, cavitation, tip vortex and multiple scales of unsteady fluctuations. One example of this type in aerospace is related to liquid-fueled rocket turbopump. Rocket turbopumps operate under severe conditions at very high rotational speeds typically at thousands of rpm. For example, the Shuttle orbiter low-pressure-fuel-turbopump creates transient flow features associated with reverse flows, tip clearance effects, secondary flows, vortex shedding, junction flows, and cavitation effects. Flow unsteadiness originating from the orbiter Low-Pressure-Fuel-Turbopump (LPFTP) inducer is one of the major contributors to the high frequency cyclic loading that results in high cycle fatigue damage to the flow liners just upstream of the LPFTP. The reverse flow generated at the tip of the inducer blades travels upstream and interacts with the bellows cavity. Simulation procedure for this type high-speed hydrodynamic problems requires a method for quantifying multi-scale and multi-phase flow as well as an efficient high-end computing strategy. The current paper presents a high-fidelity computational procedure for unsteady hydrodynamic problems using a high-speed liquid-fueled rocket turbopump.

Kiris, Cetin C.↗
NASA NTRS2001

Advanced Finite Element Modeling of Low Cycle Fatigue Crack Growth

This document (a viewgraph presentation) assumes a crack-like defect of a size which may be missed in inspection will exist in most critical location of any critical structure or component. Flaw existence assumption is usually, but not always, conservative based on past experiences in NASA and knowledge of manufacturing processes. Cyclic, environmental, and sustained loads used to generate stresses on models. Fracture Mechanics analysis used to predict crack growth and residual strength. Must show that defective structure will still provide four times required mission lifetime. Special exemptions cover redundant structures, low risk parts, etc. Assessments require specialized software tools, experienced analysts, and reliable material crack growth rate test database.

Gregg, Wayne↗
NASA NTRS1994

Thermomechanical Fatigue Damage/Failure Mechanisms in SCS-6/Timetal 21S [0/90](Sub S) Composite

The thermomechanical fatigue (TMF) deformation, damage, and life behaviors of SCS6/Timetal 21S (0/90)s were investigated under zero-tension conditions. In-phase (IP) and out-of-phase (OP) loadings were investigated with a temperature cycle from 150 to 650 deg C. An advanced TMF test technique was used to quantify mechanically damage progression. The technique incorporated explicit measurements of the macroscopic (1) isothermal static moduli at the temperature extremes of the TMF cycle and (2) coefficient of thermal expansion (CTE) as functions of the TMF cycles. The importance of thermal property degradation and its relevance to accurate post-test data analysis and interpretation is briefly addressed. Extensive fractography and metallography were conducted on specimens from failed and interrupted tests to characterize the extent of damage at the microstructure level. Fatigue life results indicated trends analogous to those established for similar unidirectional(0) reinforced titanium matrix composite systems. High stress IP and mid to low stress OP loading conditions were life-limiting in comparison to maximum temperature isothermal conditions. Dominant damage mechanisms changed with cycle type. Damage resulting from IP TMF conditions produced measurable decreases in static moduli but only minimal changes in the CTE. Metallography on interrupted and failed specimens revealed extensive (0) fiber cracking with sparse matrix damage. No surface initiated matrix cracks were present. Comparable OP TMF conditions initiated environment enhanced surface cracking and matrix cracking initiated at (90) fiber/matrix (F/M) interfaces. Notable static moduli and CTE degradations were measured. Fractography and metallography revealed that the transverse cracks originating from the surface and (90) F/M interfaces tended to converge and coalesce at the (0) fibers.

Castelli, Michael G.↗
DOE OSTI2025

A Combined Computational and Mathematical Analysis of Interconnect Fatigue Potential in Photovoltaic Modules

A finite element model of a 60-cell monocrystalline silicon glass-polymer photovoltaic module was simulated with ±1.0 kPa and ±2.4 kPa loads applied to the glass to calculate the deformation under load. Cell-to-cell displacements were used to approximate interconnect strain and stress. A mathematical fatigue cycle life relation was fitted to data for the interconnect material (copper), to generate a life prediction at each interconnect location based on the local stress means, reversal extents, and amplitudes. Interconnect stress was found to be significantly asymmetric about zero despite symmetric positive and negative module loads due to laminate thickness offsets about the neutral plane and the effects of module framing. Cycle life results indicated that interconnect fatigue failure was unlikely to occur over a 30-year lifetime of conservative wind and snow load cycles since the typical cell design feature of leaving some unconstrained length between the cell edge and first solder pad increases the effective gauge length and decreases the stress levels below the material endurance limit. Follow-up analyses found that 3.6 mm and 6.4 mm were the minimum unconstrained lengths required to survive the assumed lifetime of wind and snow cycles, respectively, confirming that typical industrial module constructions with 8–15 mm unconstrained lengths should survive conservatively. Notably, large magnitude, low-cycle snow loading was consistently the limiting factor requiring a longer unconstrained interconnect length. Finally, insights and workflows from this study inform module interconnection design limits for survival against mechanical fatigue in deployment environments.

14 SOLAR ENERGY↗
DOE OSTI2021

Fatigue behavior of fine-grained magnesium under tension-tension loading at 0 °C

Here, this study investigated low-temperature fatigue behavior of fine-grained magnesium through tension–tension fatigue testing at the temperature of 0 °C. The applied stress profiles of fatigue testing were selected to cover a wide range of loading conditions including low, medium, and high loading stresses. Even when the maximum applied stress of fatigue testing was as high as 88% of the ultimate tensile strength of the material, the corresponding fatigue life was long, i.e., 3973 cycles. Deformation accumulation per loading cycle reduced with the progression of fatigue testing for all studied loading conditions. Fatigue life analyses were performed using both Smith-Watson-Topper (SWT) model and Jahed-Varvani energy-based (JV) model. The fatigue life predictions through both models agree well with the experimental data.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Advanced Environmental Barrier Coating and SA Tyrannohex SiC Composites Integration for Improved Thermomechanical and Environmental Durability

The development of 2700 degF capable environmental barrier coating (EBC) systems, particularly, the Rare Earth "Hafnium" Silicon bond coat systems, have significantly improved the temperature capability and environmental stability of SiC/SiC Ceramic Matrix Composite Systems. We have specifically developed the advanced 2700 degF EBC systems, integrating the EBC to the high temperature SA Tyrannohex SiC fiber composites, for comprehensive performance and durability evaluations for potential turbine engine airfoil component applications. The fundamental mechanical properties, environmental stability and thermal gradient cyclic durability performance of the EBC - SA Tyrannohex composites were investigated. The paper will particularly emphasize the high pressure combustion rig recession, cyclic thermal stress resistance and thermomechanical low cycle fatigue testing of uncoated and environmental barrier coated Tyrannohex SiC SA composites in these simulated turbine engine combustion water vapor, thermal gradients, and mechanical loading conditions. We have also investigated high heat flux and flexural fatigue degradation mechanisms, determined the upper limits of operating temperature conditions for the coated SA composite material systems in thermomechanical fatigue conditions. Recent progress has also been made by using the self-healing rare earth-silicon based EBCs, thus enhancing the SA composite hexagonal fiber columns bonding for improved thermomechanical and environmental durability in turbine engine operation environments. More advanced EBC- composite systems based on the new EBC-Fiber Interphases will also be discussed.

Tyrannohex SiC Ceramics↗
NASA NTRS2020

Effect of a Large Population of Seeded Alumina Inclusions on Crack Initiation and Small Crack Fatigue Crack Growth in Udimet 720 Nickel-Base Disk Superalloy

Crack initiation, crack coalescence and small crack growth behavior were monitored for over 400 seeded inclusions during interrupted low cycle fatigue testing conducted on the P/M Udimet 720 nickel disk alloy at 650°C. Two types of seeded alumina inclusions with average sizes of 54 μm and 122 μm were used in the study performed at varying loading conditions resulting in LCF lives ranging from 2,000 cycles to over 1,000,000 cycles. The fatigue behavior was sub-categorized into four groups. Visual maps detailing inclusion size/cycle history were developed. The effect of surface residual stresses on the fatigue life was also investigated.

Superalloys↗
NASA NTRS1998

Thermomechanical Fatigue Durability of T650-35/PMR-15 Sheet Molding Compound

Although polyimide based composites have been used for many years in a wide variety of elevated temperature applications, very little work has been done to examine the durability and damage behavior under more prototypical thermomechanical fatigue (TMF) loadings. Synergistic effects resulting from simultaneous temperature and load cycling can potentially lead to enhanced, if not unique, damage modes and contribute to a number of nonlinear deformation responses. The goal of this research was to examine the effects of a TMF loading spectrum, representative of a gas turbine engine compressor application, on a polyimide sheet molding compound (SMC). High performance SMCs present alternatives to prepreg forms with great potential for low cost component production through less labor intensive, more easily automated manufacturing. To examine the issues involved with TMF, a detailed experimental investigation was conducted to characterize the durability of a T650-35/PMR-15 SMC subjected to TMF mission cycle loadings. Fatigue damage progression was tracked through macroscopic deformation and elastic stiffness. Additional properties, such as the glass transition temperature (T(sub g) and dynamic mechanical properties were examined. The fiber distribution orientation was also characterized through a detailed quantitative image analysis. Damage tolerance was quantified on the basis of residual static tensile properties after a prescribed number of TMF missions. Detailed microstructural examinations were conducted using optical and scanning electron microscopy to characterize the local damage. The imposed baseline TMF missions had only a modest impact on inducing fatigue damage with no statistically significant degradation occurring in the measured macroscopic properties. Microstructural damage was, however, observed subsequent to 100 h of TMF cycling which consisted primarily of fiber debonding and transverse cracking local to predominantly transverse fiber bundles. The TMF loadings did introduce creep related effects (strain accumulation) which led to rupture in some of the more aggressive stress scenarios examined. In some cases this creep behavior occurred at temperatures in excess of 150 C below commonly cited values for T(sub g). Thermomechanical exploratory creep tests revealed that the SMC was subject to time dependent deformation at stress/temperature thresholds of 150 MPa/230 C and 170 MPa/180 C.

Castelli, Michael G.↗
NASA NTRS1976

Stress analysis, thermomechanical fatique evaluation, and root subcomponent testing of gamma/gamma prime-delta eutectic alloy

Thermomechanical fatigue (TMF) and root subcomponent tensile, creep, and low cycle fatigue (LCF) tests were conducted to determine the capability of a fully lamellar directionally solidified eutectic alloy to sustain the airfoil thermal fatigue and root attachment loads anticipated in advanced, hollow, high work turbine blades. A three dimensional finite element elastic stress analysis was performed on typical advanced hollow eutectic airfoil and root-platform designs to determine appropriate conditions for these tests. Results of TMF tests conducted on longitudinal specimens (stress axis parallel to the solidification direction) containing a simulated leading edge cooling hole pattern indicated the longitudinal TMF properties to be more than adequate for the particular advanced hollow blade analyzed, with the strain range for a 10,000 cycle life being more than 50% above the maximum strain range calculated for the advanced hollow blade.

Sheffler, K. D.↗
NASA NTRS1975

Acoustic emission characteristics of copper alloys under low-cycle fatigue conditions

The acoustic emission (AE) characteristics of pure copper, zirconium-copper, and several copper alloys were determined to develop nondestructive evaluation schemes of thrust chambers through AE techniques. The AE counts rms voltages, frequency spectrum, and amplitude distribution analysis evaluated AE behavior under fatigue loading conditions. The results were interpreted with the evaluation of wave forms, crack propagation characteristics, as well as scanning electron fractographs of fatigue-tested samples. AE signals at the beginning of a fatigue test were produced by a sample of annealed alloys. A sample of zirconium-containing alloys annealed repeatedly after each fatigue loading cycle showed numerous surface cracks during the subsequent fatigue cycle, emitting strong-burst AE signals. Amplitude distribution analysis exhibits responses that are characteristic of certain types of AE signals.

Krampfner, Y.↗