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A system for cyclicly applying a varying load to a material under test is described. It includes a load sensor which senses the magnitude of load being applied to a material, and, upon sensing a selected magnitude of loading, causes the load to be maintained for a predetermined time and then cause the system to resume cyclical loading.
Load-deflection relationships for different types of elliptical contacts such as those found in a ball bearing are developed. Simplified expressions that allow quick calculations of deformation to be made simply from a knowledge of the applied load, the material properties, and the geometry of the contacting elements are presented. Ball bearings subjected to radial, thrust and combined ball loads are analyzed. A design criterion for fatigue life of ball bearings is developed. The section of a satisfactory lubricant, as well as describing systems that provide a constant flow of lubricant to the contact, is considered.
The design of prospective NASA space station components which inherently possess the means for structural growth without compromising initial system characteristics is considered. In structural design terms, space station growth can be achieved by increasing design safety factors, introducing dynamic isolators to prevent loads from reaching the initial components, or preplanning the refurbishment of the original structure with stronger elements. Design tradeoffs will be based on the definition of on-orbit loads, including docking and maneuvering, whose derived load spectra will allow the estimation of fatigue life. Improvements must be made in structural materials selection in order to reduce contamination, slow degradation, and extend the life of coatings. To minimize on-orbit maintenance, long service life lubrication systems with advanced sealing devices must be developed.
An evaluation is conducted of the ability of a crack-closure model to predict the fatigue life of notched specimens under spectrum loading, for the cases of crack initiation and growth along the bore of a semicircular notch and the growth of large cracks in 2024-T3 Al alloy sheets under constant-amplitude loading. These cases are used to establish an initial defect size and relationship between the stress-intensity factor range and crack-growth rate. Experimental and calculation results for small-crack growth rates are in good agreement and exhibited a stress level effect at equal values of stress-intensity factor range.
Research and development in light-weight, high-temperature composite materials for ultrahigh-bypass engines to be used in high-speed civil transport/rotocraft is presented. It is noted that the expected benefits to be attained by this R&D include weight reduction, lowered fuel consumption, and lower direct operating costs. A major effort underway in this area is the Advanced High Temperature Engine Materials Technology Program (HITEMP) of NASA, which focuses on providing revolutionary high-temperature composite materials: to 425 C (800 F) for polymer-matrix composites (PMCs), to 1250 C (2280 F) for metal-matrix/intermetallic-matrix composites (MMCs/IMCs), and to as high as 1650 C (3000 F) for ceramic-matrix composites (CMCs). Analytical modeling is being used to investigate the structural behavior of these advanced materials in six distinct areas: micromechanics, deformation and damage, fatigue, fracture, trade-off studies, and load definition. It is concluded that the development of advanced materials such as high-temperature composites is highly dependent on the availability of high-temperature fibers. The wide range of fiber characteristics needed will require the development of more than one fiber. In general, a candidate fiber should have low density, high strength, high stiffness, a CTE matching the matrix, chemical compatibility with the matrix, environmental stability and appropriate fiber diameter.
Several layups of SCS-6/Ti-15-3 composites were investigated. Fatigue tests were conducted and analyzed for both notched and unnotched specimens at room temperature and elevated temperatures. Thermo-mechanical fatigue results were analyzed. Test results indicated that the stress in the 0 degree fibers is the controlling factor in fatigue life. The static and fatigue strength of these materials is shown to be strongly dependent on the level of residual stresses and the fiber/matrix interfacial strength. Fatigue tests of notched specimens showed that cracks can initiate and grow many fiber spacings in the matrix materials without breaking fibers. Fiber bridging models were applied to characterize the crack growth behavior. The matrix cracks are shown to significantly reduce the residual strength of notched composites. The notch strength of these composites was accurately predicted using a micromechanics based methodology.
Several layups of SCS-6/Ti-15-3 composites were investigated. Fatigue tests were conducted and analyzed for both notched and unnotched specimens at room temperature and elevated temperatures. Thermo-mechanical fatigue results were analyzed. Test results indicated that the stress in the 0 degree fibers is the controlling factor in fatigue life. The static and fatigue strength of these materials is shown to be strongly dependent on the level of residual stresses and the fiber/matrix interfacial strength. Fatigue tests of notched specimens showed that cracks can initiate and grow many fiber spacings in the matrix materials without breaking fibers. Fiber bridging models were applied to characterize the crack growth behavior. The matrix cracks are shown to significantly reduce the residual strength of notched composites. The notch strength of these composites was accurately predicted using a micromechanics based methodology.
This paper reports the study of four time-frequency transforms applied to vibration signals and presents a new metric for comparing them for fault detection. The four methods to be described and compared are the Short Time Frequency Transform (STFT), the Choi-Williams Distribution (WV-CW), the Continuous Wavelet Transform (CWT) and the Discrete Wavelet Transform (DWT). Vibration data of bevel gear tooth fatigue cracks, under a variety of operating load levels, are analyzed using these methods. The new metric for automatic fault detection is developed and can be produced from any systematic numerical representation of the vibration signals. This new metric reveals indications of gear damage with all of the methods on this data set. Analysis with the CWT detects mechanical problems with the test rig not found with the other transforms. The WV-CW and CWT use considerably more resources than the STFT and the DWT. More testing of the new metric is needed to determine its value for automatic fault detection and to develop methods of setting the threshold for the metric.
In this paper, the authors show a detailed analysis of the vibration signal from the destructive testing of a spiral bevel gear and pinion pair containing seeded faults. The vibration signal is analyzed in the time domain, frequency domain and with four time-frequency transforms: the Short Time Frequency Transform (STFT), the Wigner-Ville Distribution with the Choi-Williams kernel (WV-CW), the Continuous Wavelet' Transform (CWT) and the Discrete Wavelet Transform (DWT). Vibration data of bevel gear tooth fatigue cracks, under a variety of operating load levels and damage conditions, are analyzed using these methods. A new metric for automatic anomaly detection is developed and can be produced from any systematic numerical representation of the vibration signals. This new metric reveals indications of gear damage with all of the time-frequency transforms, as well as time and frequency representations, on this data set. Analysis with the CWT detects changes in the signal at low torque levels not found with the other transforms. The WV-CW and CWT use considerably more resources than the STFT and the DWT. More testing of the new metric is needed to determine its value for automatic anomaly detection and to develop fault detection methods for the metric.
This report is a summary of the work performed by Georgia Tech Research Institute (GTRI) under NASA Langley Grant NAG-1-2146, which was awarded as a part of NASA's Breakthrough Innovative Technologies (BIT) initiative. This was a three-year program, with a one-year no-cost extension. Each year's study has been an integrated effort consisting of computational fluid dynamics, experimental aerodynamics, and detailed noise and flow measurements. Year I effort examined the feasibility of reducing airframe noise by replacing the conventional wing systems with a Circulation Control Wing (CCW), where steady blowing was used through the trailing edge of the wing over a Coanda surface. It was shown that the wing lift increases with CCW blowing and indeed for the same lift, a CCW wing was shown to produce less noise. Year 2 effort dealt with a similar study on the role of pulsed blowing on airframe noise. The main objective of this portion of the study was to assess whether pulse blowing from the trailing edge of a CCW resulted in more, less, or the same amount of radiated noise to the farfield. Results show that a reduction in farfield noise of up to 5 dB is measured when pulse flow is compared with steady flow for an equivalent lift configuration. This reduction is in the spectral region associated with the trailing edge jet noise. This result is due to the unique advantage that pulsed flow has over steady flow. For a range of frequencies, more lift is experienced with the same mass flow as the steady case. Thus, for an equivalent lift and slot height, the pulsed system can operate at lower jet velocities, and hence lower jet noise. The computational analysis showed that for a given time-averaged mass flow rate, pulsed jets give a higher value of C(sub l) and a higher L/D than equivalent steady jets. This benefit is attributable to higher instantaneous jet velocities, and higher instantaneous C(sub mu) values for the pulsed jet. Pulsed jet benefits increase at higher frequencies. However, these advantages are somewhat offset by the unsteadiness in the loads, which will cause structural vibrations and fatigue. Additional studies must be done, perhaps with multiple jets on the upper and lower surfaces, to smooth out the fluctuations in lift while retaining the benefits. The rest of the effort was devoted to examining ways of reducing flap edge noise by blowing air through a Coanda nozzle over a rounded tip of the flap. In this case, we were successful in moving the tip vortex away from the tip, but the device producing the blowing was noisy and we were unable to examine the noise benefits, although we believe that the movement of the tip vortex far from the tip should provide noise benefits. It should be noted that in an effort to understand the fluid dynamics and the aeroacoustics of a jet blowing over a Coanda surface, we also carried out a very extensive study of the high aspect ratio slot jets. A first-ever set of far-field noise spectra were measured for jets exhausting from slots with aspect ratios in the range 100 to 3000. Parallel measurements of velocity profiles, length scales and convection velocities were measured to understand the noise generation of high aspect ratio jets. Attempts were also made to develop jet noise prediction schemes for such jets. Much of the work done under this effort has been described in five conference papers and two doctoral theses. The first year s work on the use of steady blowing was described in two AIAA papers presented at the 2001 AIAA Aerospace Sciences Meeting in Reno. Subsequent work was presented at the 9th AIMCEAS Aeroacoustics Conference and Exhibit held at Hilton Head May 12-13. Another paper is to be presented at the 2004 AIAA Aerospace Sciences Meeting in Reno in January 2004. All six papers are included with this report as Appendices. The bulk of the experimental work done in an effort to produce a pulsed flow that is free of upstream noise is also attached as an Appendix.
The elastic-plastic fracture mechanics modules in NASGRO have been enhanced by the addition of of the following: new J-integral solutions based on the reference stress method and finite element solutions; the extension of the critical crack and critical load modules for cracks with two degrees of freedom that tear and failure by ductile instability; the addition of a proof test analysis module that includes safe life analysis, calculates proof loads, and determines the flaw screening 1 capability for a given proof load; the addition of a tear-fatigue module for ductile materials that simultaneously tear and extend by fatigue; and a multiple cycle proof test module for estimating service reliability following a proof test.
Systems, methods, and apparatus for increasing durability of adhesively bonded joints in a sandwich structure. Such systems, methods, and apparatus includes an first face sheet and an second face sheet as well as an insert structure, the insert structure having a first insert face sheet, a second insert face sheet, and an insert core material. In addition, sandwich core material is arranged between the first face sheet and the second face sheet. A primary bondline may be coupled to the face sheet(s) and the splice. Further, systems, methods, and apparatus of the present disclosure advantageously reduce the load, provide a redundant path, reduce structural fatigue, and/or increase fatigue life.
Systems, methods, and apparatus for increasing durability of adhesively bonded joints in a sandwich structure. Such systems, methods, and apparatus includes an first face sheet and an second face sheet as well as an insert structure, the insert structure having a first insert face sheet, a second insert face sheet, and an insert core material. In addition, sandwich core material is arranged between the first face sheet and the second face sheet. A primary bondline may be coupled to the face sheet(s) and the splice. Further, systems, methods, and apparatus of the present disclosure advantageously reduce the load, provide a redundant path, reduce structural fatigue, and/or increase fatigue life.
Tests were performed to determine the damage states in quasi-isotropic graphite/epoxy laminates with center holes caused by cyclic tensile loading. The influence of the stacking sequence on the initiation and interaction of damage modes and the relationship between damage, strength, stiffness, and life of the laminates were also studied. X-ray radiography, moire interferometry, and stiffness change were used to monitor damage. Fatigue damage in both laminates began with matrix cracks around the holes leading to delaminations. In laminates cycled at the same percent of notched tensile strength the stacking sequence influenced the density of the matrix cracks and the modes and distribution of the damage. Ply cracking was also caused by the stacking sequence. The damage states in the two laminates produced stiffness changes of 15 to 20 percent, different rates of change in residual strength, and a factor of two to four difference in fatigue life. It was determined that continued cyclic loading produced matrix cracks which led to fatigue of the laminates.
Announced survey directs attention toward low cycle fatigue and thermal fatigue experienced at elevated temperatures equivalent to those found in hot end of gas turbine engine. Majority of bibliographic references are on life prediction for materials exposed to monotonic and cyclic loading in high temperature environments.
The viability of a method for determining the fatigue life of composite rotor hub flexbeam laminates using delamination fatigue characterization data and a geometric non-linear finite element (FE) analysis was studied. Combined tension and bending loading was applied to non-linear tapered flexbeam laminates with internal ply drops. These laminates, consisting of coupon specimens cut from a full-size S2/E7T1 glass-epoxy flexbeam were tested in a hydraulic load frame under combined axial-tension and transverse cyclic bending. The magnitude of the axial load remained constant and the direction of the load rotated with the specimen as the cyclic bending load was applied. The first delamination damage observed in the specimens occurred at the area around the tip of the outermost ply-drop group. Subsequently, unstable delamination occurred by complete delamination along the length of the specimen. Continued cycling resulted in multiple delaminations. A 2D finite element model of the flexbeam was developed and a geometrically non-linear analysis was performed. The global responses of the model and test specimens agreed very well in terms of the transverse displacement. The FE model was used to calculate strain energy release rates (G) for delaminations initiating at the tip of the outer ply-drop area and growing toward the thick or thin regions of the flexbeam, as was observed in the specimens. The delamination growth toward the thick region was primarily mode 2, whereas delamination growth toward the thin region was almost completely mode 1. Material characterization data from cyclic double-cantilevered beam tests was used with the peak calculated G values to generate a curve predicting fatigue failure by unstable delamination as a function of the number of loading cycles. The calculated fatigue lives compared well with the test data.
The viability of a method for determining the fatigue life of composite rotor hub flexbeam laminates using delamination fatigue characterization data and a geometric non-linear finite element (FE) analysis was studied. Combined tension and bending loading was applied to nonlinear tapered flexbeam laminates with internal ply drops. These laminates, consisting of coupon specimens cut from a full-size S2/E7T1 glass-epoxy flexbeam were tested in a hydraulic load frame under combined axial-tension and transverse cyclic bending loads. The magnitude of the axial load remained constant and the direction of the load rotated with the specimen as the cyclic bending load was applied. The first delamination damage observed in the specimens occurred at the area around the tip of the outermost ply-drop group. Subsequently, unstable delamination occurred by complete delamination along the length of the specimen. Continued cycling resulted in multiple delaminations. A 2D finite element model of the flexbeam was developed and a geometrically non-linear analysis was performed. The global responses of the model and test specimens agreed very well in terms of the transverse flexbeam tip-displacement and flapping angle. The FE model was used to calculate strain energy release rates (G) for delaminations initiating at the tip of the outer ply-drop area and growing toward the thick or thin regions of the flexbeam, as was observed in the specimens. The delamination growth toward the thick region was primarily mode 2, whereas delamination growth toward the thin region was almost completely mode 1. Material characterization data from cyclic double-cantilevered beam tests was used with the peak calculated G values to generate a curve predicting fatigue failure by unstable delamination as a function of the number of loading cycles. The calculated fatigue lives compared well with the test data.
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.