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At least 1,207 records · Page 67

Fatigue crack propagation behavior of the Ni-Ni3Cb eutectic composite

The experimental procedures used in the investigation are considered, taking into account solidification and heat treatment, fatigue testing, questions of test specimen and loading fixture design verification, metallographic techniques, and electron microscopy techniques. Attention is given to the characteristics of the microstructure, aspects of fatigue crack propagation (FCP) in the Ni-Ni3Nb composite, the effect of test variables on FCP, the effect of metallurgical variables on FCP, and fatigue fracture mechanisms. Fractographic and metallographic observations are discussed.

Mills, W. J.↗

Impact tests on fibrous composite sandwich structures

The effect of low velocity impact on the strength of laminates fabricated from graphite/epoxy and Kevlar 49/epoxy composite materials was studied. The test laminates were loaded statically either in uniaxial tension or compression when impact occurred to evaluate the effect of loading on the initiation of damage and/or failure. Typical aircraft service conditions such as runway debris encountered during landing were simulated by impacting 1.27-cm-diameter projectiles normal to the plane of the test laminates at velocities between 5.2 and 48.8 m/s.

Rhodes, M. D.↗

Considerations in STS payload environmental verification

Considerations regarding the Space Transportation System (STS) payload environmental verification are reviewed. It is noted that emphasis is placed on testing at the subassembly level and that the basic objective of structural dynamic payload verification is to ensure reliability in a cost-effective manner. Structural analyses consist of: (1) stress analysis for critical loading conditions, (2) model analysis for launch and orbital configurations, (3) flight loads analysis, (4) test simulation analysis to verify models, (5) kinematic analysis of deployment/retraction sequences, and (6) structural-thermal-optical program analysis. In addition to these approaches, payload verification programs are being developed in the thermal-vacuum area. These include the exposure to extreme temperatures, temperature cycling, thermal-balance testing and thermal-vacuum testing.

Keegan, W. B.↗

Application of a gripping system to test a uniaxial graphite fiber reinforced composite /PMR 15/Celion 6000/ in tension at 316 C

A gripping system has been developed to test uniaxial, 0 deg orientation PMR 15/Celion 6000 composites at elevated temperatures. The method involves compression of grit-blasted laminate between grit-blasted metal to give a non-slipping interface for load transfer. Tensile testing at both 316 C and room temperature indicated that deformation was elastic to fracture and that the variation in tensile properties for one laminate is the same as that for several panels. In addition, the tensile properties for uniaxial PMR 15/Celion 6000 are identical at 316 C and room temperature. For nominally 51 volume percent fiber, the elastic modulus is 119.6 GPa, the fracture stress is 1370 MPa, and the strain to fracture is about 1.15 percent. In addition, data are presented which indicate that the gripping system can be used for long term, elevated temperature testing of composite materials.

Whittenberger, J. D.↗

Characterizing Face Sheet/Core Disbonding Using the Single Cantilever Beam Test: Results from an International Round Robin

Test results from an international round robin are presented. The single cantilever beam (SCB) test was used to characterize face sheet/core disbonding in sandwich components in an effort to help standardization. Each of the seven participating laboratories performed a set of five baseline tests using the same protocol, however, using their own specific equipment. In addition, each laboratory performed two sets of tests with altered tests conditions which included using a test fixture with a translating carriage and performing the tests with different loading and unloading speeds. The orientation of the disbond front with respect to the honeycomb core cells was varied and the effect on the fracture toughness was also studied. Additional factors that could influence test results were investigated, such as the use of a saw cut starter disbond as an alternative to Teflon® release film, and the effects of using a face sheet doubler to increase the bending stiffness. For each set of tests, summary results such as load/displacements plots, observed disbond growth location and calculated energy release rates are reported and a comparison of results between labs is presented. Critical strain energy release rate measurements from SCB tests are also compared with measurements made from an alternative test, namely the double cantilever beam with uneven bending moments (DCB-UBM) test, which has been studied extensively at the Technical University of Denmark and proposed as a mixed-mode test standard. A set of recommendations are made with respect to improving the SCB test and a path to standardization is presented.

Ronald Krueger↗

Fuel cell technology program

A fuel cell technology program was established to advance the state-of-the-art of hydrogen-oxygen fuel cells using low temperature, potassium hydroxide electrolyte technology as the base. Program tasks are described consisting of baseline cell design and stack testing, hydrogen pump design and testing, and DM-2 powerplant testing and technology extension efforts. A baseline cell configuration capable of a minimum of 2000 hours of life was defined. A 6-cell prototype stack, incorporating most of the scheme cell features, was tested for a total of 10,497 hours. A 6-cell stack incorporating all of the design features was tested. The DM-2 powerplant with a 34 cell stack, an accessory section packaged in the basic configuration anticipated for the space shuttle powerplant and a powerplant control unit, was defined, assembled, and tested. Cells were used in the stack and a drag-type hydrogen pump was installed in the accessory section. A test program was established, in conjunction with NASA/JSC, based on space shuttle orbiter mission. A 2000-hour minimum endurance test and a 5000-hour goal were set and the test started on August 8, 1972. The 2000-hour milestone was completed on November 3, 1972. On 13 March 1973, at the end of the thirty-first simulated seven-day mission and 5072 load hours, the test was concluded, all goals having been met. At this time, the DM-2 was in excellent condition and capable of additional endurance.

Source record↗

Verification of rain-flow reconstructions of a variable amplitude load history

The suitability of using rain-flow reconstructions as an alternative to an original loading spectrum for component fatigue life testing is investigated. A modified helicopter maneuver history is used for the rain-flow cycle counting and history regenerations. Experimental testing on a notched test specimen over a wide range of loads produces similar lives for the original history and the reconstructions. The test lives also agree with a simplified local strain analysis performed on the specimen utilizing the rain-flow cycle count. The rain-flow reconstruction technique is shown to be a viable test spectrum alternative to storing the complete original load history, especially in saving computer storage space and processing time. A description of the regeneration method, the simplified life prediction analysis, and the experimental methods are included in the investigation.

Clothiaux, John D.↗

TEAMER: Biofouling Analysis for Wave Energy Piston Design - Load Cell Data

Biofouling and corrosion are a major concern for all ocean-deployed components, especially when mechanical motion is involved. Triton has developed the concept of a biofouling mitigation seal as part of the piston sealing assembly for the Triton Wave Energy Converter (TSI-WEC). This mitigation seal has the purpose of preventing the formation of a biofilm on the inside of the piston cylinder. It is hypothesized that the prevention of a biofilm will reduce the amount of macro-biofouling that can occur in the piston assembly. The mitigation seal can also reduce the wear on the main dynamic seal, helping to maintain smooth operation and water-tightness. The cylinder is made from a thermoset composite epoxy, which is resistant to corrosion. However, no studies have researched the material's performance with biofouling. Triton placed two prototype Power Take-Off (PTO) assemblies in a PNNL biofouling tank, one with a biofouling mitigation seal and one without, allowing for an evaluation of seal effectiveness at the prevention of biofouling. In actual WEC operation, wave action would react against the piston, which would drive the linear actuator and electric generator, providing electrical power. In the test setup, this was reversed; a linear actuator was powered to drive the piston in a consistent motion within the cylinder. There are two assemblies: one has a biofouling mitigation seal, the other (control) does not. The following data encompasses a 4 month test period, with load cells being used to monitor piston friction force. Results from this testing will be used to improve seal design and material selection, mitigating risk of premature failure during open water testing and evaluation. This project is part of the TEAMER RFTS 3 (request for technical support) program.

16 TIDAL AND WAVE POWER↗

Design, fabrication and test of graphite/polymide composite joints and attachments: Summary

The design, analysis and testing performed to develop four types of graphite/polyimide (Gr/PI) bonded and bolted composite joints for lightly loaded control surfaces on advanced space transportation systems that operate at temperatures up to 561K (550 F) are summarized. Material properties and 'small specimen' tests were conducted to establish design data and to evaluate specific design details. 'Static discriminator' tests were conducted on preliminary designs to verify structural adequacy. Scaled up specimens of the final joint designs, representative of production size requirements, were subjected to a series of static and fatigue tests to evaluate joint strength. Effects of environmental conditioning were determined by testing aged (125 hours 589K (600 F)) and thermal cycled (116K to 589K (-250 F to 600 F), 125 times) specimens. It is concluded Gr/PI joints can be designed and fabricated to carry the specified loads. Test results also indicate a possible resin loss or degradation of laminates after exposure to 589K (600 F) for 125 hours.

Cushman, J. B.↗

Large-bore tapered-roller bearing performance and endurance to 2.4 million DN

The operating characteristics and experimental life estimates for 120.65 mm bore tapered roller bearings of two designs under combined radial and thrust loads were determined. A modified standard bearing design was tested at speeds up to 15,000 rpm. A computer optimized, high speed design was tested at speeds up to 20,000 rpm. Both designs were tested at a combined load of 26,700 N (6000 lb) radial load and and 53,400 N (12,000 lb) thrust load. Advanced helicopter transmissions which require the higher-speed capability of tapered-roller bearings also require higher temperature capability (ref. 2). Thus, materials with temperature capabilities higher than the conventional carburizing steels are required.

Parker, R. J.↗

Structural Stability of a Stiffened Aluminum Fuselage Panel Subjected to Combined Mechanical and Internal Pressure Loads

Results from an experimental and analytical study of a curved stiffened aluminum panel subjected to combined mechanical and internal pressure loads are presented. The panel loading conditions were simulated using a D-box test fixture. Analytical buckling load results calculated from a finite element analysis are presented and compared to experimental results. Buckling results presented indicate that the buckling load of the fuselage panel is significantly influenced by internal pressure loading. The experimental results suggest that the stress distribution is uniform in the panel prior to buckling. Nonlinear finite element analysis results correlates well with experimental results up to buckling.

Rouse, Marshall↗

Fatigue Life Analysis of Tapered Hybrid Composite Flexbeams

Nonlinear-tapered flexbeam laminates from a full-size composite helicopter rotor hub flexbeam were tested under combined constant axial tension and cyclic bending loads. The two different graphite/glass hybrid configurations tested under cyclic loading failed by delamination in the tapered region. A 2-D finite element model was developed which closely approximated the flexbeam geometry, boundary conditions, and loading. The analysis results from two geometrically nonlinear finite element codes, ANSYS and ABAQUS, are presented and compared. Strain energy release rates (G) obtained from the above codes using the virtual crack closure technique (VCCT) at a resin crack location in the flexbeams are presented for both hybrid material types. These results compare well with each other and suggest that the initial delamination growth from the resin crack toward the thick region of the flexbeam is strongly mode II. The peak calculated G values were used with material characterization data to calculate fatigue life curves and compared with test data. A curve relating maximum surface strain to number of loading cycles at delamination onset compared reasonably well with the test results.

Murri, Gretchen B.↗

Experimental Studies of Low-Load Limit in a Stoichiometric Micro-Pilot Diesel Natural Gas Engine

While operating at light loads, diesel pilot-ignited natural gas engines with lean premixed natural gas suffer from poor combustion efficiency and high methane emissions. This work investigates the limits of low-load operation for a micro-pilot diesel natural gas engine that uses a stoichiometric mixture to enable methane and nitrogen oxide emission control. By optimizing engine hardware, operating conditions, and injection strategies, this study focused on defining the lowest achievable load while maintaining a stoichiometric equivalence ratio and with acceptable combustion stability. A multi-cylinder diesel 6.7 L engine was converted to run natural gas premix with a maximum diesel micro-pilot contribution of 10%. With a base diesel compression ratio of 17.3:1, the intake manifold pressure limit was 80 kPa(absolute). At a reduced compression ratio of 15:1, this limit increased to 85 kPa, raising the minimum stable load. Retarding the combustion phasing, typically used in spark-ignition engines to achieve lower loads, was also tested but found to be limited by degraded diesel ignition at later timings. Reducing the pilot injection pressure improved combustion stability, as did increasing pilot quantity at the cost of lower substitution ratios. The lean operation further reduced load but increased NOx and hydrocarbon emissions. At loads below the practical dual-fuel limit, a transition to lean diesel operation will likely be required with corresponding implications for the aftertreatment system.

03 NATURAL GAS↗

Shear testing of fiber reinforced metal matrix composites

This paper outlines the elements of a combined experimental/analytical methodology for accurate shear characterization of unidirectional composites in the linear and nonlinear range, with particular attention devoted to metal matrix composites. It is illustrated that consistent results can be obtained for a large class of composites from two commonly employed shear test methods currently in use by composites researchers when the influence of various factors that affect the determination of the actual shear response is properly analyzed. These factors include the effects of material anisotropy, specimen geometry, manner of load introduction, and test fixture design on the stress and deformation fields in the test section of off-axis and Iosipescu specimens. Common errors associated with the measurement of deformation fields and calculation of stress fields are discussed and quantified. Particular problems in the determination of the shear response of unidirectional boron/aluminum using the Iosipescu test are illustrated and discussed.

Pindera, Marek-Jerzy↗

Nacelle Aerodynamic and Inertial Loads (NAIL) project

A flight test survey of pressures measured on wing, pylon, and nacelle surfaces and of the operating loads on Boeing 747/Pratt & Whitney JT9D-7A nacelles was made to provide information on airflow patterns surrounding the propulsion system installations and to clarify processes responsible for inservice deterioration of fuel economy. Airloads at takeoff rotation were found to be larger than at any other normal service condition because of the combined effects of high angle of attack and high engine airflow. Inertial loads were smaller than previous estimates indicated. A procedure is given for estimating inlet airloads at low speeds and high angles of attack for any underwing high bypass ratio turbofan installation approximately resembling the one tested. Flight procedure modifications are suggested that may result in better fuel economy retention in service. Pressures were recorded on the core cowls and pylons of both engine installations and on adjacent wing surfaces for use in development of computer codes for analysis of installed propulsion system aerodynamic drag interference effects.

Source record↗

Compression After Impact Testing of Sandwich Structures Using the Four Point Bend Test

For many composite laminated structures, the design is driven by data obtained from Compression after Impact (CAI) testing. There currently is no standard for CAI testing of sandwich structures although there is one for solid laminates of a certain thickness and lay-up configuration. Most sandwich CAI testing has followed the basic technique of this standard where the loaded ends are precision machined and placed between two platens and compressed until failure. If little or no damage is present during the compression tests, the loaded ends may need to be potted to prevent end brooming. By putting a sandwich beam in a four point bend configuration, the region between the inner supports is put under a compressive load and a sandwich laminate with damage can be tested in this manner without the need for precision machining. Also, specimens with no damage can be taken to failure so direct comparisons between damaged and undamaged strength can be made. Data is presented that demonstrates the four point bend CAI test and is compared with end loaded compression tests of the same sandwich structure.

Nettles, Alan T.↗

Dual hologram design study

A phase modulated triple exposure technique was incorporated into a holographic nondestructive test (HNDT) system. The technique was able to achieve a goal of simultaneously identifying the zero-order fringe and determining the direction of motion (or displacement). Basically, the technique involves the addition of one more exposure, during the loading of the tested object, to the conventional double-exposure hologram. A phase shifter is added to either the object beam or the reference beam during the second and third exposure. Theoretical analysis with the assistance of computer simulation illustrated the feasibility of implementing the phase modulation and triple-exposure in the HNDT systems. Main advantages of the technique are the enhancement of accuracy in data interpretation and a better determination of the nature of the flaws in the tested object.

Liu, H. K.↗

Crack Branching and Fracture Mirror Data of Glasses and Advanced Ceramics

The fracture mirror and crack branching constants were determined from three glasses and nine advanced ceramics tested under various loading and specimen configurations in an attempt to use the constants as a data base for fractography. The ratios of fracture mirror or crack branching constant to fracture toughness were found to be approximately two for most ceramic materials tested. A demonstration of how to use the two constants as a tool for verifying stress measurements was presented for silicon nitride disk specimens subjected to high-temperature, constant stress-rate biaxial flexure testing.

Choi, Sung R.↗