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The objective is to enable the student to generate statistically sound fatigue data sets on wire specimens of varying diameter, microstructure, or material. The student can then assess the effect of these parameters of fatigue resistance. The student can also be exposed to ASTM techniques for fatigue data reduction and presentation. Experiments involving variable amplitude block loading are also easily conducted.
The issue of fatigue loading of structures composed of composite materials is considered in a requirements document that is currently in place for manned launch vehicles. By taking into account the short life of these parts, coupled with design considerations, it is demonstrated that the necessary coupon level fatigue data collapse to a static case. Data from a literature review of past studies that examined compressive fatigue loading after impact and data generated from this experimental study are presented to support this finding. Damage growth, in the form of infrared thermography, was difficult to detect due to rapid degradation of compressive properties once damage growth initiated. Unrealistically high fatigue amplitudes were needed to fail 5 of 15 specimens before 10,000 cycles were reached. Since a typical vehicle structure, such as the Ares I interstage, only experiences a few cycles near limit load, it is concluded that static compression after impact (CAI) strength data will suffice for most launch vehicle structures.
The development of a reusable space shuttle by NASA in the next decade depends in part on the design of a satisfactory thermal protection system (TPS). The booster and orbiter parts of the shuttle require TPS panels which will withstand thermoacoustic fatigue. The Langley Research Center has begun tests on early panel designs in a new acoustic fatigue facility which is capable of simulating the combined elevated temperature and acoustic environments which these panels are expected to experience. The capabilities of the facility and computer system are outlined, and problems encountered in establishing the test methods are discussed. Tests of a Haynes 25 TPS panel are described, and representative data from tests of the panel at 650 C are included.
A computer program was developed for data acquisition and control of axial-torsional fatigue experiments. The multitasked, interrupt-driven program was written in Pascal and Assembly. This program is capable of dual-channel control and six-channel data acquisition. It can be utilized to perform inphase and out-of-phase axial-torsional isothermal fatigue or deformation experiments. The program was successfully used to conduct inphase axial-torsional fatigue experiments on 304 stainless steel at room temperature and on Hastelloy X at 800 C. The details of the software and some of the results generated to date are presented.
A computer program was developed for data acquisition and control of axial-torsional fatigue experiments. The multitasked, interrupt-driven program was written in Pascal and Assembly. This program is capable of dual-channel control and six-channel data acquisition. It can be utilized to perform inphase and out-of-phase axial-torsional isothermal fatigue or deformation experiments. The program was successfully used to conduct inphase axial-torsional fatigue experiments on 304 stainless steel at room temperature and on Hastelloy X at 800 C. The details of the software and some of the results generated to date are presented.
Passive thermography is a large area inspection technique and is commonly used during fatigue loading of composite structures. Passive thermography allows for real time tracking of damage. This provides an accurate assessment of the damage progression as a function of load cycles and determines when the loading is stopped for ultrasonic or X-ray CT evaluations for detail damage assessment through-the-thickness. In addition, if new areas of damage growth are detected, with passive thermography, then those areas are additionally inspected with ultrasound or X-ray CT. A custom developed passive thermography inspection system for fatigue loading is presented. Passive thermography of damage progression is compared to ultrasound inspections as a function of the fatigue cycles. Discussion is made on processing of the thermal data for periodic and non-periodic thermal responses.
Burner rig tests on simulated turbine blades, with and without internal cooling, to predict thermal fatigue performance
An investigation pertaining to the development of life prediction methods for materials subjected to high temperature creep/fatigue conditions is presented. High frequency (13.4 kHz) fatigue data were measured at 1400 F on specimens of the nickel-based alloy Udimet 700. Tests were conducted on the virgin material, as well as on specimens which had received prior exposures to high temperature, fatigue, and creep.
A great deal of research has been performed characterizing the in-plane fiber-dominated properties, under both static and fatigue loading, of advanced composite materials. To the author's knowledge, no study has been performed to date investigating fatigue characteristics in the transverse direction. This information is important in the design of bonded composite airframe structure where repeated, cyclic out-of-plane bending may occur. Recent tests characterizing skin/stringer debond failures in reinforced composite panels where the dominant loading in the skin is flexure along the edge of the frame indicate failure initiated either in the skin or else the flange, near the flange tip. When failure initiated in the skin, transverse matrix cracks formed in the surface skin ply closest to the flange and either initiated delaminations or created matrix cracks in the next lower ply, which in turn initiated delaminations. When failure initiated in the flanges, transverse cracks formed in the flange angle ply closest to the skin and initiated delamination. In no configuration did failure propagate through the adhesive bond layer. For the examined skin/flange configurations, the maximum transverse tension stress at failure correlates very well with the transverse tension strength of the composites. Transverse tension strength (static) data of graphite epoxy composites have been shown to vary with the volume of material stressed. As the volume of material stressed increased, the strength decreased. A volumetric scaling law based on Weibull statistics can be used to predict the transverse strength measurements. The volume dependence reflects the presence of inherent flaws in the microstructure of the lamina. A similar approach may be taken to determine a volume scale effect on the transverse tension fatigue behavior of graphite/epoxy composites. The objective of this work is to generate transverse tension strength and fatigue S-N characteristics for composite materials using 3-point flexure tests of 90 deg graphite/epoxy specimens. Investigations will include the volume scale effect as well as frequency and span-to-thickness ratio effects. Prior to the start of the experimental study, an analytical study using finite element modeling will be performed to investigate the span-to-thickness effect. The ratio of transverse flexure stress to shear stress will be monitored and its values predicted by the FEM analysis compared with the value obtained using a 'strength of materials' based approach.
Ceramic thermal barrier coatings will play an increasingly important role in future gas turbine engines because of their ability to effectively protect the engine components and further raise engine temperatures. Durability of the coating systems remains a critical issue with the ever-increasing temperature requirements. Thermal conductivity increase and coating degradation due to sintering and phase changes are known to be detrimental to coating performance. There is a need to characterize the coating thermal fatigue behavior and temperature limit, in order to potentially take full advantage of the current coating capability. In this study, thermal conductivity and cyclic fatigue behaviors of plasma-sprayed ZrO2-8wt%Y2O3 thermal barrier coatings were evaluated under high temperature, large thermal gradient and thermal cycling conditions. The coating degradation and failure processes were assessed by real-time monitoring of the coating thermal conductivity under the test conditions. The ceramic coating crack initiation and propagation driving forces and failure modes under the cyclic thermal loads will be discussed in light of the high temperature mechanical fatigue and fracture testing results.
A technique using a point contact piezoelectric detector has been developed which permits the displacement amplitude distributions over the entire length of high frequency fatigue specimens to be measured. Elastic strain distributions can be derived with a computer analysis that uses curve smoothing and numerical derivative methods. The equipment and techniques for measuring and processing the data are described, and displacement amplitudes, strain distributions, and magnification factors for straight rods and dumbbell-shaped specimens are obtained and shown to agree with theoretically predicted values. It is shown that the technique presented here can be used to design specimens with unusual displacement amplitudes and strain distributions.
Multiaxial testing methods are reviewed. Advantages and disadvantages of each type test is discussed. Significant multiaxial data available in the literature is analyzed. The yield theories are compared for multiaxial fatigue analysis.
Cycle life data are presented in terms of true maximum strain for four metals, two plastics, and two elastomers. The Coffin-Manson fatigue theory was applied for metals and plastics, and cut-growth fatigue theory for elastomers. The data are based on measurements made at room and elevated temperatures. It was found that double folds give rise to far severer folding strains than do simple folds. It was also found that, except for the elastomers, all the bladder materials develop surface cracks due to double folds after only one cycle. The findings indicate that metals, which are bets for premeation resistance, are worst for fatigue resistance, and vice versa for elastomers. The intermediate plastics were found to be unsatisfactory for both permeation and fatigue resistance for missions of extended duration.
A pair of corrugation stiffened, beaded skin Rene 41 heat shield panels were exposed to 20,000 thermal cycles between room temperature and 1450 F to evaluate the thermal fatigue response of Rene 41 metallic heat shields for hypersonic cruise aircraft applications. At the conclusion of the tests, the panels retained substantial structural integrity; however, there were cracks and excessive wear in the vicinity of fastener holes and there was an 80-percent loss in ductility of the skin. Shrinkage of the panel which caused the cracks and wear must be considered in design of panels for Thermal Protection Systems (TPS) applications.
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The good design of highly stressed mechanical components requires accurate knowledge of the service behavior of materials. The main methods for solving the problems of designers are: determination of the mechanical properties of the material after cyclic stabilization; plotting of resistance to plastic deformation curves; effect of temperature on the life on low cycle fatigue; and simulation of notched parts behavior.
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A hydrogen-oxygen subscale rocket combustion chamber was designed incorporating an advanced design concept to reduce strain and increase life. The design permits unrestrained thermal expansion of a circumferential direction and, thereby, provides structural compliance during the thermal cycling of hot-fire testing. The chamber was built and test fired at a chamber pressure of 4137 kN/sq m (600 psia) and a hydrogen-oxygen mixture ratio of 6.0. Compared with a conventional milled-channel configuration, the new structurally compliant chamber had a 134 or 287 percent increase in fatigue life, depending on the life predicted for the conventional configuration.