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At least 1,135 records · Page 63

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NASA NTRS1985

Permafrost and Subsurface Ice in the Solar System

The properties and behavior of planetary permafrost are discussed with reference to the ability of such surfaces to sustain loads characteristics of spacecraft landing and planetary bases. In most occurrences, water ice is in close proximity to, or in contact with, finely divided silicate mineral matter. When ice contacts silicate mineral surfaces, a liquid-like, transition zone is created. Its thickness ranges from several hundred Angstron units at temperatures near 0 degrees C to about three Angstrom units at -150 degrees C. When soluble substances are present, the resulting brine enlarges the interfacial zone. When clays are involved, although the interfacial zone may be small, its extent is large. The unfrozen, interfacial water may amount to 100% or more weight at a temperature of -5 degrees C. The presence of this interfacial unfrozen water acts to confer plasticity to permafrost, enabling it to exhibit creep at all imposed levels of stress. Nucleation processes and load-bearing capacity are examined.

Anderson, D. M.↗

DOE OSTI2022

Residual elastic strain evolution due to thermal cycling of a ceramic-metal composite (WC-Cu) via high energy X-ray diffraction and analytical modeling

Residual stress, when superimposed with in-service loading, can significantly reduce the lifetime and performance of a component. Ceramic-metal composites are susceptible to residual stresses due to the thermal expansion mismatch of the ceramic and metallic phases. The WC-Cu composite explored in the present study provides a promising combination of thermal conductivity and strength properties, while exhibiting counterintuitive improvements in strength and ductility after thermal cycling. Further, this work quantifies the evolution of the residual elastic strains as a result of processing and cyclic thermal loading in a co-continuous WC-Cu composite through experimental high energy X-ray diffraction and kinetics-based modeling. Both analyses indicate that processing-induced residual tensile stress in the copper phase is relieved upon subsequent thermal cycling, with kinetics modeling revealing the cyclic-dependent nature of the active power-law creep mechanisms. The results indicate that, through stress relaxation, this material system maintains structural stability during thermal cycling. The illustrated kinetics of relaxation can inform general material processors and designers of ceramic-metal composites to minimize detrimental residual stress and improve performance of these material systems.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Rolling Bearing Life Prediction, Theory, and Application

A tutorial is presented outlining the evolution, theory, and application of rolling-element bearing life prediction from that of A. Palmgren, 1924; W. Weibull, 1939; G. Lundberg and A. Palmgren, 1947 and 1952; E. Ioannides and T. Harris, 1985; and E. Zaretsky, 1987. Comparisons are made between these life models. The Ioannides-Harris model without a fatigue limit is identical to the Lundberg-Palmgren model. The Weibull model is similar to that of Zaretsky if the exponents are chosen to be identical. Both the load-life and Hertz stress-life relations of Weibull, Lundberg and Palmgren, and Ioannides and Harris reflect a strong dependence on the Weibull slope. The Zaretsky model decouples the dependence of the critical shear stress-life relation from the Weibull slope. This results in a nominal variation of the Hertz stress-life exponent. For 9th- and 8th-power Hertz stress-life exponents for ball and roller bearings, respectively, the Lundberg-Palmgren model best predicts life. However, for 12th- and 10th-power relations reflected by modern bearing steels, the Zaretsky model based on the Weibull equation is superior. Under the range of stresses examined, the use of a fatigue limit would suggest that (for most operating conditions under which a rolling-element bearing will operate) the bearing will not fail from classical rolling-element fatigue. Realistically, this is not the case. The use of a fatigue limit will significantly overpredict life over a range of normal operating Hertz stresses. (The use of ISO 281:2007 with a fatigue limit in these calculations would result in a bearing life approaching infinity.) Since the predicted lives of rolling-element bearings are high, the problem can become one of undersizing a bearing for a particular application. Rules had been developed to distinguish and compare predicted lives with those actually obtained. Based upon field and test results of 51 ball and roller bearing sets, 98 percent of these bearing sets had acceptable life results using the Lundberg- Palmgren equations with life adjustment factors to predict bearing life. That is, they had lives equal to or greater than that predicted. The Lundberg-Palmgren model was used to predict the life of a commercial turboprop gearbox. The life prediction was compared with the field lives of 64 gearboxes. From these results, the roller bearing lives exhibited a load-life exponent of 5.2, which correlated with the Zaretsky model. The use of the ANSI/ABMA and ISO standards load-life exponent of 10/3 to predict roller bearing life is not reflective of modern roller bearings and will underpredict bearing lives.

Life prediction↗

NASA NTRS1990

Test and model correlation of the atmospheric emission photometric imager fiberglass pedestal

The correlation is presented of the static loads testing and finite element modeling for the fiberglass pedestal used on the Atmospheric Emission Photometric Imaging (AEPI) experiment. This payload is to be launched in the space shuttle as part of the ATLAS-1 experiment. Strain gauge data from rosettes around the highly loaded base are compared to the same load case run for the Spacelab 1 testing done in 1981. Correlation of the model and test data was accomplished through comparison of the composite stress invariant using the expected flight loads for the ATLAS-1 mission. Where appropriate, the Tsai-Wu failure criteria was used in the development of the key margins of safety. Margins of safety are all positive for the pedestal and are reported.

Lee, H. M., III↗

NASA NTRS2020

Evaluation of Fatigue Damage Accumulation Functions for Delamination Initiation and Propagation

The present report follows on the cohesive fatigue damage model methodology proposed in NASA-TP-2018-219838. In that report, an empirical function describing the incremental damage due to cyclic loading was used to calculate fatigue damage within a cohesive formulation. The form of the function was developed such that, when integrated at a constant stress amplitude from no damage to failure, it produces a life versus load response that is consistent with an S-N diagram. Therefore, the parameters of the damage model could be obtained by fitting the model predictions to an S-N diagram. The finite element analyses performed demonstrate that the cohesive fatigue accumulation function provides a link between the S-N diagram that describes crack initiation, and the Paris law that characterizes the rate of crack propagation. However, when the model was proposed, it was not known whether the form of the damage accumulation function associated with a desired S-N diagram is unique and, if not, if the link between S-N and the Paris law is unique and independent of the fatigue function selected. In the effort described herein, several alternative forms of the damage function that reproduce the desired features of S-N diagrams were found and evaluated. The effects of each of these functions on the predicted parameters of the Paris law and the propagation threshold are discussed. The results indicate that the predicted exponent m of the Paris law is indeed independent of the damage accumulation function. However, different functions predict different values for the pre-factor C of the Paris law. Therefore, the proper damage accumulation function must be selected by comparison with experiments. One of the new damage accumulation functions proposed herein was found to be particularly useful for analysis because of the ease with which the model parameters can be determined with a minimal amount of experimental information. The effectiveness of the proposed methodology and damage function was demonstrated by conducting analyses of a double cantilever beam test, a mixed-mode bending test, and a three-point bending test of a skin/doubler specimen. The results indicate that the same set of model parameters can provide accurate predictions of the rate of fatigue crack propagation for a variety of material interfaces, mode mixities, load levels, and stress ratios.

Cohesive elements↗

DOE OSTI2024

Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System

The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS1975

Fatigue life of organic fiber/epoxy pressure vessels

The cyclic fatigue life of 10.2-cm-diam cylindrical pressure vessels has been studied. The vessels were made of an organic fiber/epoxy composite. To determine the typical strength distribution of the vessels, 25 of them were internally pressurized until they burst. Twenty-five vessels were then tested under sinusoidal cycling at 1 Hz between 4% and 91% of the mean burst strength. An additional twenty-five vessels were tested between 4% and 91% with a rectangular pressure pulse at 1/3 Hz. A limited number of vessels were tested for stress rupture at the 91% level. Cyclic life was found to depend on time at peak load as well as the number of stress cycles.

Hamstad, M. A.↗

NASA NTRS1980

Microstructural characterization of the HRSI thermal protection system for space shuttle

Components of the space shuttle high temperature reusable surface insulation (HRSI) system were microscopically characterized, both separately and as a system, to obtain information needed for stress analysis models of the thermal protection system. A tension specimen of the HRSI system was loaded in steps and was microscopically observed at each load condition to demonstrate the tension failure mode associated with strain isolation pad (SIP) behavior. A local failure occurred which should be associated with transfer of load through transverse fibers in the SIP. Stress concentrations attributed to the SIP behavior necessitated strengthening of the HRSI by densification of the RSI at the bondline. An HRSI tile was microscopically characterized after the densification process. The densified surface layer blended into the RSI which caused a gradual change in density. The gradation in density does not appear to represent a sharp discontinuity in elastic modulus between the densified layer and the parent material.

Ransone, P. O.↗

NASA NTRS1934

Torsional stresses in box beams with cross sections partially restrained against warping

The present report gives a method for computing the torsion of boxes with thin shear-resistant or simply tension-resistant walls under any torsional load, support and dimension. The final stress condition is developed from that of a principal system with unconstrained sectional warping corresponding to Bredt's formula and an additional stress condition due to constrained cross-sectional warping. This is computed by means of the deflection condition of the principal system from a statically indeterminate calculation. Conformably, the torsional rigidity of the final system is derived from that of the principal system with unconstrained sectional buckling.

Ebner, Hans↗

NASA NTRS1930

Bending Tests of Metal Monocoque Fuselage Construction

This thesis presents a study of the bending stress in smooth skin, aluminum alloy, true monocoque fuselage sections of varying ratio of diameters to thickness. The test specimens - circular, thin-walled cylinder were loaded to give a large bending stress in proportion to the shearing stress, in order to represent the critical section of a fuselage.

Mossman, Ralph W↗

NASA NTRS1992

Optical and TEM study of shock metamorphism from the Sedan test site

Thus far, detailed petrologic studies of shock metamorphism have been performed on samples recovered from laboratory experiments and on a few natural impactites. The loading history of these samples is quite different: In particular, laboratory experiments spend only a short time (less than 1 microsec) at peak pressure, whereas natural impactites may have stress pulses from 0.1 - 1 ms. On the other hand, laboratory experiments have known stress histories; natural impactites do not. Natural samples are also subjected to thousands or millions of years of postshock annealing and/or weathering. A useful intermediate case is that of nuclear detonation. Stress pulses for these events can reach 0.1 ms or higher, and samples are obtained in pristine condition. All three types of loading produce stresses of hundreds of kilobars. Samples studied were taken from the Sedan nulcear test site, and consist of a coarse-grained granodiorite containing quartz, K-feldspar, cordierite, and hornblende. Samples were studied optically in this section, then were thinned with an ion mill and studied by transmission electron microscopy (TEM). Optically, quartz and K-feldspar displayed numerous sets of planar deformation features (PDF's) identical to the nondecorated PDF's seen in laboratory samples and many natural impactites. TEM study showed that the PDF's in quartz and feldspar corresponded to densely packed wide transformation lamellae identical to those described in laboratory studies. The transformation lamellae in both minerals were amorphous, with no sign of high-pressure phases. In the case of K-feldspar only, narrow sublamellae extended outward from some wide lamellae. Quartz, which was more abundant and studied more extensively, contained no shock-induced dislocations. Some planar features were also seen in cordierite, but could not be identified due to rapid beam damage. No shock defects were seen in hornblende in TEM. The shock-induced defects present at the Sedan site are very similar to those seen in shock recovery experiments, and also to those present at certain natural events (e.g., Meteor Crater). This suggests that shock deformation in quartz is not strongly dependent on shock pulse duration, and that laboratory recovery experiments are useful simulations of natural impact events.

Gratz, A. J.↗

NASA NTRS1993

An approximate solution for interlaminar stresses in composite laminates

An efficient approximate solution for interlaminar stresses in finite width, symmetric and unsymmetric laminated composites subjected to axial and/or bending loads is presented. The solution is based upon statically admissible stress fields which take into consideration local property mismatch effects and global equilibrium requirements. Unknown constants in the assumed stress states are determined through minimization of the laminate complementary energy. Typical results are presented for through-thickness and interlaminar stress distributions for angle-ply and cross-ply laminates subjected to axial loading. It is shown that the present formulation represents an improved, efficient approximate solution for interlaminar stresses.

Rose, Cheryl A.↗

NASA NTRS1959

Experimental Investigation of Effects of Random Loading on the Fatigue Life of Notched Cantilever-Beam Specimens of 7075-T6 Aluminum Alloy

Results of random-loading fatigue tests on 125 notched cantilever-beam specimens and constant-amplitude fatigue tests on 46 similar specimens are presented in terms of the root-mean-square value of peak stresses. The results from the two sets of tests are compared on the basis of time to failure, where the results from the constant-amplitude tests are expressed in terms of an equivalent time to failure based on the natural period of vibration. Compared on this basis, failure at the lower stress levels occurred in a shorter time for the random loading than for the constant-amplitude loading, whereas at the higher stress levels failure occurred in the reverse order. A theoretical result for random loading is also presented and compared with the experimental results. The theoretical result shows good agreement with experiment for low values of stress but underestimates the time to failure at the higher stresses.

Fralich, Robert W.↗

NASA NTRS1982

Impact resistance of fiber composites

Stress-strain curves are obtained for a variety of glass fiber and carbon fiber reinforced plastics in dynamic tension, over the stress-strain range of 0.00087-2070/sec. The test method is of the one-bar block-to-bar type, using a rotating disk or a pendulum as the loading apparatus and yielding accurate stress-strain curves up to the breaking strain. In the case of glass fiber reinforced plastic, the tensile strength, strain to peak impact stress, total strain and total absorbed energy all increase significantly as the strain rate increases. By contrast, carbon fiber reinforced plastics show lower rates of increase with strain rate. It is recommended that hybrid composites incorporating the high strength and rigidity of carbon fiber reinforced plastic with the high impact absorption of glass fiber reinforced plastics be developed for use in structures subjected to impact loading.

Chamis, C. C.↗

DOE OSTI2024

Agrivoltaic Racking Design Optimization Based on Wind and Snow Loading Finite Element Analysis

The racking structure of photovoltaic (PV) systems plays a critical role in ensuring the PV panels generate power properly as it provides integral structural support and sometimes even solar tracking ability. Distinct applications of PV systems require variations of racking structure designs, which yield different mechanical performances under external loading conditions from the environment, such as heavy wind and snow. Past works, such as Reddy et al. [1], have analyzed the pressure effects of wind and snow loading on the racking structure of conventional rooftop and utility PV systems, but there is little knowledge of how various agrivoltaic racking systems perform, in terms of stress and strain, under the same loading conditions. There is also a knowledge gap in the industry on a set of optimized agrivoltaic racking design standards. This study investigates the mechanical performance of various existing racking systems and proposes novel designs that are optimized for agrivoltaics applications under wind and snow loading.

Liao, Quanhuan↗

NASA NTRS1982

Fatigue of graphite/epoxy /0/90/45/-45/s laminates under dual stress levels

A model for the prediction of loading sequence effects on the statistical distribution of fatigue life and residual strength in composite materials is generalized and applied to (0/90/45/-45)s graphite/epoxy laminates. Load sequence effects are found to be caused by both the difference in residual strength when failure occurs (boundary effect) and the effect of previously applied loads (memory effect). The model allows the isolation of these two effects, and the estimation of memory effect magnitudes under dual fatigue loading levels. It is shown that the material memory effect is insignificant, and that correlations between predictions of the number of early failures agree with the verification tests, as do predictions of fatigue life and residual strength degradation under dual stress levels.

Yang, J. N.↗

NASA NTRS1978

Mode I analysis of a cracked circular disk subject to a couple and a force

Mode I stress intensity coefficients were obtained for an edge-cracked disk (round compact specimen). Results for this plane elastostatic problem, obtained by a boundary collocation analysis are presented for A/D ratios of 0.35 to 1, where A is the crack length and D is the disk diameter. The results presented are for two complementary types of loading. By superposition of these results the stress intensity factor for any practical load line location of a pin-loaded round compact specimen can be obtained.

Gross, B.↗

DOE OSTI2023

Direct comparison between experiments and dislocation dynamics simulations of high rate deformation of single crystal copper

A long standing challenge in computational materials science is to establish a quantitative connection between the macroscopic properties of plastic deformation with the microscopic mechanisms of dislocations in crystalline materials. Although the discrete dislocation dynamics (DDD) simulation method has been developed for several decades with the goal of addressing this challenge, a one-to-one comparison between the DDD predictions on single crystal stress–strain curves and experimental measurements under identical conditions has not been possible to date. Such a comparison is an essential step towards establishing a dislocation-physics based theory of plasticity and a multiscale framework of the plastic behaviors of crystalline materials. Here we provide direct comparisons between the stress–strain curves of Cu single crystals under high strain rate loading in the [0 0 1] and [0 1 1] directions obtained from miniaturized desktop Kolsky bar experiments and those from DDD simulations under identical loading conditions. With an appropriate set of parameters, DDD simulations can produce stress–strain curves that are in reasonable agreement with the experimental results. However, the dislocation mobility values needed to achieve this agreement are an order of magnitude lower than expected based on previous measurements and atomistic simulations. We hypothesize that this discrepancy could be caused by drag forces from jogs and point defects produced during the plastic deformation. Cross-slip of screw dislocations is also found to be necessary to capture the experimental stress–strain behavior, especially for the [0 1 1] loading direction. Finally, this work provides an example of how direct comparisons between DDD simulations and experimental measurements can provide new insight into the fundamental mechanisms of plastic deformation.

36 MATERIALS SCIENCE↗