Fatigue Investigation of Full-Scale Transport-Airplane Wings: Variable-Amplitude Tests with a Gust-Loads Spectrum
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Whaley, Richard E↗
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Some Strength Tests of Stiffened Curved Sheets Loaded in Shear
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STRESSED SKIN - SHELLS, CYLINDRICAL↗
Preliminary Investigation and Design of an Air-heated Wing for Lockheed 12A Airplane
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WINGS - LOCKHEED 12A-LOAD TESTS↗
Proposed framework for thermomechanical life modeling of metal matrix composites
The framework of a mechanics of materials model is proposed for thermomechanical fatigue (TMF) life prediction of unidirectional, continuous-fiber metal matrix composites (MMC's). Axially loaded MMC test samples are analyzed as structural components whose fatigue lives are governed by local stress-strain conditions resulting from combined interactions of the matrix, interfacial layer, and fiber constituents. The metallic matrix is identified as the vehicle for tracking fatigue crack initiation and propagation. The proposed framework has three major elements. First, TMF flow and failure characteristics of in situ matrix material are approximated from tests of unreinforced matrix material, and matrix TMF life prediction equations are numerically calibrated. The macrocrack initiation fatigue life of the matrix material is divided into microcrack initiation and microcrack propagation phases. Second, the influencing factors created by the presence of fibers and interfaces are analyzed, characterized, and documented in equation form. Some of the influences act on the microcrack initiation portion of the matrix fatigue life, others on the microcrack propagation life, while some affect both. Influencing factors include coefficient of thermal expansion mismatch strains, residual (mean) stresses, multiaxial stress states, off-axis fibers, internal stress concentrations, multiple initiation sites, nonuniform fiber spacing, fiber debonding, interfacial layers and cracking, fractured fibers, fiber deflections of crack fronts, fiber bridging of matrix cracks, and internal oxidation along internal interfaces. Equations exist for some, but not all, of the currently identified influencing factors. The third element is the inclusion of overriding influences such as maximum tensile strain limits of brittle fibers that could cause local fractures and ensuing catastrophic failure of surrounding matrix material. Some experimental data exist for assessing the plausibility of the proposed framework.
Halford, Gary R.↗
Review of modelling small-crack behavior and fatigue-life predictions for aluminum alloys
The small-crack effect, where small fatigue cracks grow faster and at lower stress-intensity factors than large cracks, has been found to be significant for many materials and loading conditions. In this paper, plasticity effects and crack-closure modelling of small fatigue cracks are reviewed. A crack-closure model with a cyclic-plastic-zone-corrected effective stress-intensity factor range (related to the cyclic J-integral) and microstructural data on crack-initiation sites were used to calculate small-crack growth rates and fatigue lives for unnotched and notched specimens made of two aluminum alloys. The crack-closure transient from the plastic wake was shown to be the dominant cause of the small-crack effect and plasticity effects on the cyclic-plastic-zone-corrected stress-intensity factor range were negligible except at extremely high stress levels. Small-crack growth rates and fatigue lives under both constant-amplitude and spectrum loading from tests and analyses agreed well.
CRACK CLOSURE MODELLING↗
Parallel volume ray-casting for unstructured-grid data on distributed-memory architectures
As computing technology continues to advance, computational modeling of scientific and engineering problems produces data of increasing complexity: large in size and unstructured in shape. Volume visualization of such data is a challenging problem. This paper proposes a distributed parallel solution that makes ray-casting volume rendering of unstructured-grid data practical. Both the data and the rendering process are distributed among processors. At each processor, ray-casting of local data is performed independent of the other processors. The global image composing processes, which require inter-processor communication, are overlapped with the local ray-casting processes to achieve maximum parallel efficiency. This algorithm differs from previous ones in four ways: it is completely distributed, less view-dependent, reasonably scalable, and flexible. Without using dynamic load balancing, test results on the Intel Paragon using from two to 128 processors show, on average, about 60% parallel efficiency.
Ma, Kwan-Liu↗
A Review Of Modelling Small-Crack Behavior And Fatigue-Life Predictions For Aluminum Alloys
The small-crack effect, where small fatigue cracks grow faster and at lower stress-intensity factors than large cracks, has been found to be significant for many materials and loading conditions. In this paper, plasticity effects and crack-closure modelling of small fatigue cracks are reviewed. A crack-closure model with a cyclic-plastic zone-corrected effective stress-intensity factor range (related to the cyclic J-integral) and microstructural data on crack-initiation sites were used to calculate small-crack growth rates and fatigue lives for unnotched and notched specimens made of two aluminum alloys. The crack-closure transient from the plastic wake was shown to be the dominant cause of the small-crack effect and plasticity effects on the cyclic-plastic zone-corrected stress-intensity factor range were negligible except at extremely high stress levels. Small-crack growth rates and fatigue lives under both constant-amplitude and spectrum loading from tests and analyses agreed well.
Newman, J. C., Jr.↗
Elevated-Temperature Deformation Properties of a HfC Modified Ti-48Al-2Mn-2Nb Matrix Particulate Composite
Rapid solidification techniques in combination with HIPing have been used to produce Ti-48Al-2Mn-2Nb and a Ti-48Al-2Mn-2Nb+15 wt% HfC composite. While the composite does contain several second phases within the gamma + alpha(sub 2) matrix, none was identified to be HfC. The elevated-temperature properties were determined by constant velocity compression and constant load tensile testing in air between 1000 and 1173 K. Such testing indicated that the elevated temperature strengths of the HfC-modified aluminide was superior to those of the unreinforced matrix with the best 1100 K temperature slow strain rate properties for both materials being achieved after high-temperature annealing prior to testing. Examination of the microstructures after deformation in combination with the measured stress exponents and activation energies suggest that creep resistance of the HfC-modified form is due to solid-solution strengthening from carbon and hafnium rather than the presence of second phases.
Whittenberger, J. D.↗
Predicted Static Aeroelastic Effects on Wings with Supersonic Leading Edges and Streamwise Tips
A method is presented for calculation of static aeroelastic effects on wings with supersonic leading edges and streamwise tips. Both chord-wise and spanwise deflections are taken into account. Aerodynamic and structural forces are introduced in influence coefficient form; the former are developed from linearized supersonic wing theory and the latter are assumed to be known from load-deflection tests or theory. The predicted effects of flexibility on lateral-control effectiveness, damping in roll, and lift-curve slope are shown for a low-aspect-ratio wing at Mach numbers of 1.25 and 2.60. The control effectiveness is shown for a trailing-edge aileron, a tip aileron, and a slot-deflector spoiler located along the 0.70 chord line. The calculations indicate that the tip aileron is particularly attractive from an aeroelastic standpoint, because the changes in effectiveness with dynamic pressure are small compared to the changes in effectiveness of the trailing-edge aileron and slot-deflector spoiler. The effects of making several simplifying assumptions in the example calculations are shown. The use of a modified strip theory to determine the aerodynamic influence coefficients gave adequate results only for the high Mach number case. Elimination of chordwise bending in the structural influence coefficients exaggerated the aeroelastic effects on rolling-moment and lift coefficients for both Mach numbers.
Brown, Stuart C.↗
An Ultrasonic Technique to Determine the Residual Strength of Adhesive Bonds
In this work, ultrasonic techniques to nondestructively evaluate adhesive bond degradation have been studied. The key to the present approach is the introduction of an external factor which pulls the adhesive bond in the nonlinear range, simultaneously with the application of an ultrasonic technique. With the aid of an external static tensile loading, a superimposed longitudinal wave has.been used to obtain the slopes of the stress-strain curve of an adhesive bond at a series of load levels. The critical load, at which a reduction of the slope is detected by the superimposed longitudinal wave, is an indication of the onset of nonlinear behavior of the adhesive bond, and therefore of bond degradation. This approach has been applied to the detection of adhesive bond degradation induced by cyclic fatigue loading. Analogously to the longitudinal wave case, a superimposed shear wave has been used to obtain the effective shear modulus of adhesive layers at different shear load levels. The onset of the nonlinear behavior of an adhesive bond under shear loading has been detected by the use of a superimposed shear wave. Experiments show that a longitudinal wave can also detect the nonlinear behavior when an adhesive bond is subjected to shear loading. An optimal combination of ultrasonic testing and mechanical loading methods for the detection of degradation related nonlinear behavior of adhesive bonds has been discussed. For the purpose of a practical application, an ultrasonic technique that uses a temperature increase as an alternative to static loading has also been investigated. A general strain-temperature correspondence principle that relates a mechanical strain to a temperature has been presented. Explicit strain-temperature correspondence relations for both the tension and shear cases have been derived. An important parameter which quantifies the relation between the wave velocity and temperature has been defined. This parameter, which is indicative of adhesive bond nonlinearity and which can be conveniently obtained by an ultrasonic measurement, has been used as an indication of adhesive bond degradation. Experimental results have shown that the temperature increase method is a convenient and productive alternative to static loading. A technique which uses the reflected waveform data to obtain the fundamental ultrasonic parameters (transit time, reflection coefficient and attenuation coefficient) of an adhesive bond has also been presented.
Achenbach, J. D.↗
A Systems Approach to the Solid Lubrication of Foil Air Bearings for Oil-Free Turbomachinery
Foil air bearings are self-acting hydrodynamic bearings which rely upon solid lubricants to reduce friction and minimize wear during sliding which occurs at start-up and shut-down when surface speeds are too low to allow the formation of a hydrodynamic air film. This solid lubrication is typically accomplished by coating the non-moving foil surface with a thin, soft polymeric film. The following paper introduces a systems approach in which the solid lubrication is provided by a combination of self lubricating shaft coatings coupled with various wear resistant and lubricating foil coatings. The use of multiple materials, each providing different functions is modeled after oil-lubricated hydrodynamic sleeve bearing technology which utilizes various coatings and surface treatments in conjunction with oil lubricants to achieve optimum performance. In this study, room temperature load capacity tests are performed on journal foil air bearings operating at 14,000 rpm. Different shaft and foil coating technologies such as plasma sprayed composites, ceramic, polymer and inorganic lubricant coatings are evaluated as foil bearing lubricants. The results indicate that bearing performance is improved through the individual use of the lubricants and treatments tested. Further, combining several solid lubricants together yielded synergistically better results than any material alone.
DellaCorte, Christopher↗
Application of Laser Based Ultrasound for NDE of Damage in Thick Stitched Composites
As design engineers implement new composite systems such as thick, load bearing composite structures, they must have certifiable confidence in structure s durability and worthiness. This confidence builds from understanding the structural response and failure characteristics of simple components loaded in testing machines to tests on full scale sections. Nondestructive evaluation is an important element which can provide quantitative information on the damage initiation, propagation, and final failure modes for the composite structural components. Although ultrasound is generally accepted as a test method, the use of conventional ultrasound for in-situ monitoring of damage during tests of large structures is not practical. The use of lasers to both generate and detect ultrasound extends the application of ultrasound to in- situ sensing of damage in a deformed structure remotely and in a non-contact manner. The goal of the present research is to utilize this technology to monitor damage progression during testing. The present paper describes the application of laser based ultrasound to quantify damage in thick stitched composite structural elements to demonstrate the method. This method involves using a Q-switched laser to generate a rapid, local linear thermal strain on the surface of the structure. This local strain causes the generation of ultrasonic waves into the material. A second laser used with a Fabry-Perot interferometer detects the surface deflections. The use of fiber optics provides for eye safety and a convenient method of delivering the laser over long distances to the specimens. The material for these structural elements is composed of several stacks of composite material assembled together by stitching through the laminate thickness that ranging from 0.5 to 0.8 inches. The specimens used for these nondestructive evaluation studies had either impact damage or skin/stiffener interlaminar failure. Although little or no visible surface damage existed, internal damage was detected by laser based ultrasound.
Anastasi, Robert F.↗
Investigation of Incipient Spin Characteristics of a 1/35-Scale Model of the Convair F-102A Airplane, Coord. No. AF-AM-79
Incipient spin characteristics have been investigated on a l/35-scale dynamic model of the Convair F-10% airplane. The model was launched by a catapult apparatus into free flight with various control settings, and the motions obtained were photographed. The model was ballasted for the combat loading. All tests were made with the speed brakes and landing gear retracted, and engine effects were not simulated. The results of the investigation indicated that the model would enter motions apparently simulating entry phases of spins when the elevators were deflected full up. Deflecting the rudder had little effect on the direction of the motion obtained, but when ailerons were deflected the model always rotated in a direction opposite to the aileron setting (that is, the model entered a right spin with the stick to the left). The ailerons were very influential in initiating spin entry, and the pilot should avoid, as far as possible, the use of ailerons in low-speed flight.
Healy, Frederick M.↗
NASA Dryden Flight Research Center
This DVD has several short videos showing some of the work that Dryden is involved in with experimental aircraft. These are: shots showing the Active AeroElastic Wing (AAW) loads calibration tests, AAW roll maneuvers, AAW flight control surface inputs, Helios flight, and takeoff, and Pathfinder takeoff, flight and landing.
Navarro, Robert↗
Functional Interrupts and Destructive Failures from Single Event Effect Testing of Point-Of-Load Devices
We show examples of single event functional interrupt and destructive failure in modern POL devices. The increasing complexity and diversity of the design and process introduce hard SEE modes that are triggered by various mechanisms.
Chen, Dakai↗
Design and Fabrication Development of J-2X Engine Metallic Nozzle Extension
Maximized rocket engine performance is in part derived from expanding combustion gasses through the rocket nozzle. For upper stage engines the nozzles can be quite large. On the J-2X engine, an uncooled extension of a regeneratively cooled nozzle is used to expand the combustion gasses to a targeted exit pressure which is defined by an altitude for the desired maximum performance. Creating a J-2X nozzle extension capable of surviving the loads of test and flight environments while meeting engine system performance requirements required development of new processes and facilities. Meeting the challenges of the development resulted in concurrent J-2X nozzle extension design and fabrication. This paper describes how some of the design and fabrication challenges were resolved.
Kopicz, C.↗
Forward Skirt Structural Testing on the Space Launch System (SLS) Program
Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the NASA Space Launch System (SLS) program. Testing was needed because SLS ascent loads are 35% higher than Space Shuttle loads. Objectives of testing were to determine margins of safety, demonstrate reliability, and validate analytical models. Testing combined with analysis was able to show heritage forward skirts were acceptable to use on the SLS program.
Lohrer, J. D.↗
Damage Instability and Transition From Quasi-Static to Dynamic Fracture
In a typical mechanical test, the loading phase is intended to be a quasi-static process, while the failure and collapse is usually a dynamic event. The structural strength and modes of damage can seldom be predicted without accounting for these two aspects of the response. For a proper prediction, it is therefore essential to use tools and methodologies that are capable of addressing both aspects of responses. In some cases, implicit quasi-static models have been shown to be able to predict the entire response of a structure, including the unstable path that leads to fracture. However, is it acceptable to ignore the effect of inertial forces in the formation of damage? In this presentation we examine aspects of the damage processes that must be simulated for an accurate prediction of structural strength and modes of failure.
Davila, Carlos G.↗