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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,333 records · Page 74
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Mechanical behavior analysis using small-size graphite disc compression testing with digital image correlation methods

The ASTM International Standard Test Method for Tensile Stress-Strain of Carbon and Graphite (ASTM C749) requires dog-bone shaped specimens. Unfortunately, specimen sizes required in ASTM C749 are much too large for irradiation within a test reactor and are incompatible with irradiation capsule volumes, molten salt degradation facilities, or oxidation apparatus. The ASTM International Standard Test Method for Tensile Strength Estimate by Disc Compression of Manufactured Graphite (ASTM D8289) was developed as an alternative that provides a means for testing tensile properties using smaller specimens when geometric constraints are present. However, the important stress–strain relation throughout the test loading history that could be recorded using ASTM C749 is lost by using ASTM D8289 because of the difficulties involved with using traditional strain gauges or extensometers on such a small specimen. In this work, a digital image correlation (DIC) method, which uses a full-field noncontact surface displacement measurement technique, was applied along with the ASTM D8289 splitting tensile test on eight small samples of graphite grade Mersen 2114 to track their deformation during compressive loading. Initial results showed that the DIC technique can measure the surface displacement/strain on these small (Ø6 × 3 mm) graphite specimens with high accuracy and good repeatability, indicating that the DIC technique, combined with the small-disc splitting tensile test in ASTM D8289, can capture the strain evolution in the test. In conclusion, further comparison of measured strains with analytical and numerical simulation results provides additional understanding of the mechanical behaviour of this nuclear graphite material in complex stress states.

36 MATERIALS SCIENCE↗
NASA NTRS1977

Stability analysis of a reinforced carbon carbon shell

This paper presents the development of a stability analysis for the nose cap of the NASA Space Shuttle Orbiter. Stability is evaluated by the differential stiffness analysis of the NASTRAN finite-element computer code, addressing those nonstandard characteristics in the nose cap such as nonuniform curvature, asymmetrical and nonuniform loads, support fixity, and various combinations of membrane and bending stresses. A full-sized nose cap, thinner than production, was statically tested and stability analyzed. The failing load level correlated to within 30%. The region and mode of buckling that occurred during test was accurately predicted by analysis. The criterion for predicting instability is based on the behavior of the nonlinear deflections. The deflections are nonlinear elastic in that the stresses are well within the elastic range of the material, but the geometry-load relationship produces nonlinear deflections. The load-deflection relationship is well defined by differential stiffness analysis up to the zero-slope portion of the curve, the point of neutral stability or where the shell 'snaps through' just prior to general instability.

Agan, W. E.↗
DOE OSTI2026

Atomistic Mechanisms of Stress-Dependent Molten Salt Corrosion in NiCr Alloys

Ni-based structural alloys in molten salt environments often experience simultaneous mechanical loading and corrosive attack, yet the mechanisms governing stress-corrosion interactions remain unclear. Prior studies largely emphasize tensile stress, while the role of compressive stress has received limited attention. Here, reactive molecular dynamics simulations are used to investigate the coupled effects of applied strain and corrosion in Ni 0.75 Cr 0.25 exposed to molten FLiNaK at 800 °C. A Σ5(210) grain boundary model is subjected to tensile (+4%) to compressive (−4%) uniaxial strains, and corrosion behavior is evaluated through fluorine adsorption, charge redistribution, and grain boundary evolution. Tensile strain accelerates intergranular corrosion susceptibility by reducing local atomic packing through elastic dilation and increasing excess free volume at the grain boundary, which enhances atomic mobility and salt infiltration. In contrast, compressive strain can suppress corrosion by promoting the formation of a ridge-like surface layer along the grain boundary, limiting salt access to the underlying alloy. These results provide atomistic insight into how stress states influence grain boundary corrosion in molten salts.

36 - MATERIALS SCIENCE↗
NASA NTRS1985

Analysis of an externally radially crack ring segment subject to three-point radial loading

The boundary collocation method was used to generate Mode I stress intensity and crack mouth opening displacement coefficients for externally radially (through-the-thickness) cracked ring segments subjected to three-point radial loading. Numerical results were obtained for ring segment outer-to-inner radius ratios (Ro/Ri) ranging from 1.10 to 2.50 and crack length to segment width ratios (a/W) ranging from 0.1 to 0.8. Stress intensity and crack mouth displacement coefficients were found to depend on the ratios Ro/Ri and a/W as well as the included angle between the directions of the reaction forces.

Gross, B.↗
NASA NTRS1981

Analysis of Barkhausen noise to assess shrink fit stresses

The possible application of Barkhausen Noise Analysis to assess shrink fit stresses in steel bushings was investigated. Ten specimens of four different size NAS steel bushings were used in experiments to determine the relationship between the Barkhausen signal amplitude and the hoop-stress in the bushings. This relationship was investigated for specimens which were loaded by a simple clamping fixture and specimens subjected to actual thermal interference fits. The results show that while the relationship of Barkhausen signal amplitude to hoop stress is predictable for specimens loaded by the simple clamping fixture, the relationship was less predictable for actual thermal fit bushings. The variation in results could possibly be due to variable levels of axial stress produced by the differential thermal expansion of the steel and aluminum.

Nondestructive testing↗
DOE OSTI2021

Development of a Vibration Technique Based on Geometric Optimization for Fatigue Life Evaluation of Sandwich Composite Structures

A major obstacle to obtaining cost-effective experimental data on the fatigue life of sandwich panels is the prohibitive amount of time and cost required to carry out millions of cycles. On the other hand, vibration techniques applied to sandwich geometries fail to match the stress patterns that are obtained from standard flexural fatigue tests. To overcome such limitations, a vibration-based fatigue technique is proposed, which entails the use of sandwich specimens whose geometries are optimized to reproduce the stress distribution observed during three point bend loading while vibrating at the first resonant frequency. The proposed vibration technique was experimentally validated. The results, compared with the average number of cycles to failure at different stress ratios obtained via the Three-Point Bending test, showed high levels of accuracy. The proposed method is robust and time effective and indicates the possibility of attaining fatigue lifetime prediction of a wide class of composite elements, such as sandwich panels.

36 MATERIALS SCIENCE↗
NASA NTRS1976

Roller bearing geometry design

A theory of kinematic stabilization of rolling cylinders is extended and applied to the design of cylindrical roller bearings. The kinematic stabilization mechanism puts a reverse skew into the rolling elements by changing the roller taper. Twelve basic bearing modification designs are identified amd modeled. Four have single transverse convex curvature in their rollers while eight have rollers which have compound transverse curvature made up of a central cylindrical band surrounded by symmetric bands with slope and transverse curvature. The bearing designs are modeled for restoring torque per unit axial displacement, contact stress capacity, and contact area including dynamic loading, misalignment sensitivity and roller proportion. Design programs are available which size the single transverse curvature roller designs for a series of roller slopes and load separations and which design the compound roller bearings for a series of slopes and transverse radii of curvature. The compound rollers are proportioned to have equal contact stresses and minimum size. Design examples are also given.

Savage, M.↗
NASA NTRS1978

Effect of cyclic loading and temper condition on the tensile behavior of boron-aluminum

Experimental results from monotonic and cyclic tension tests on six different 6061 boron-aluminum laminates show that the strength of fiber dominated laminates is decreased and the strength of matrix dominated laminates is increased by T6 heat treatment. Cyrogenic exposure and cyclic loading are shown to have little influence on strength. Cyclic loading is also shown to produce small reductions in modulus for some laminates and some temper conditions. The results are discussed in light of expected metallurgical and residual stress changes due to temperature excursions and loading cycles.

Herakovich, C. T.↗
NASA NTRS1991

Using probabilistic analysis to assess the reliability of predicted SRB aft-skirt stresses

Probabilistic failure analysis is a tool to predict the reliability of a part or system. Probabalistic techniques were used to predict critical stresses which occur in the solid rocket booster aft-skirt during main engine buildup, immediately prior to lift-off. More than any other hold down post (HDP) load component, the Z loads are sensitive to variations in strains and calibration constants. Also, predicted aft-skirt stresses are strongly affected by HDP load variations. Therefore, the instrumented HDP are not effective load transducers for Z loads, and, when used with aft skirt stress indicator equations, yield estimates with large uncertainty. Monte Carlo simulation proved to be a straight forward way of studying the overlapping effects of multiple parameters on predicted equipment performance. An advantage of probabilistic analysis is the degree of uncertainty of each parameter as stated explicitly by its probability distribution. It was noted, however, that the choice of parameter distribution had a large effect on the simulation results. Many times these distributions must be assumed. The engineer who is designing the part should be responsible for the choice of parameter distribution.

Richardson, James A.↗
NASA NTRS2001

Quantifying Residual Stresses by Means of Thermoelastic Stress Analysis

This study focused on the application of the Thermoelastic Stress Analysis (TSA) technique as a tool for assessing the residual stress state of structures. TSA is based on the fact that materials experience small temperature changes when compressed or expanded. When a structure is cyclically loaded, a surface temperature profile results which correlates to the surface stresses. The cyclic surface temperature is measured with an infrared camera. Traditionally, the amplitude of a TSA signal was theoretically defined to be linearly dependent on the cyclic stress amplitude. Recent studies have established that the temperature response is also dependent on the cyclic mean stress (i.e., the static stress state of the structure). In a previous study by the authors, it was shown that mean stresses significantly influenced the TSA results for titanium- and nickel-based alloys. This study continued the effort of accurate direct measurements of the mean stress effect by implementing various experimental modifications. In addition, a more in-depth analysis was conducted which involved analyzing the second harmonic of the temperature response. By obtaining the amplitudes of the first and second harmonics, the stress amplitude and the mean stress at a given point on a structure subjected to a cyclic load can be simultaneously obtained. The experimental results showed good agreement with the theoretical predictions for both the first and second harmonics of the temperature response. As a result, confidence was achieved concerning the ability to simultaneously obtain values for the static stress state as well as the cyclic stress amplitude of structures subjected to cyclic loads using the TSA technique. With continued research, it is now feasible to establish a protocol that would enable the monitoring of residual stresses in structures utilizing TSA.

Gyekenyesi, Andrew L.↗
NASA NTRS2001

Structural Analysis of Composite Flywheels: an Integrated NDE and FEM Approach

A structural assessment by integrating finite-element methods (FEM) and a nondestructive evaluation (NDE) of two flywheel rotor assemblies is presented. Composite rotor A is pancake-like with a solid hub design, and composite rotor B is cylindrical with a hollow hub design. Detailed analyses under combined centrifugal and interference-fit loading are performed. Two- and three-dimensional stress analyses and two-dimensional fracture mechanics analyses are conducted. A comparison of the structural analysis results obtained with those extracted via NDE findings is reported. Contact effects due to press-fit conditions are evaluated. Stress results generated from the finite-element analyses were corroborated with the analytical solution. Cracks due to rotational loading up to 48,000 rpm for rotor A and 34,000 rpm for rotor B were successfully imaged with NDE and predicted with FEM and fracture mechanics analyses. A procedure that extends current structural analysis to a life prediction tool is also defined.

Abdul-Aziz, Ali↗
NASA NTRS2000

An Integrated NDE and FEM Characterization of Composite Rotors

A structural assessment by integrating finite-element methods (FEM) and a nondestructive evaluation (NDE) of two flywheel rotor assemblies is presented. Composite rotor A is pancake like with a solid hub design, and composite rotor B is cylindrical with a hollow hub design. Detailed analyses under combined centrifugal and interference-fit loading are performed. Two- and three-dimensional stress analyses and two-dimensional fracture mechanics analyses are conducted. A comparison of the structural analysis results obtained with those extracted via NDE findings is reported. Contact effects due to press-fit conditions are evaluated. Stress results generated from the finite-element analyses were corroborated with the analytical solution. Cracks due to rotational loading up to 49 000 rpm for rotor A and 34 000 rpm for rotor B were successfully imaged with NDE and predicted with FEM and fracture mechanics analyses. A procedure that extends current structural analysis to a life prediction tool is also defined.

Abdul-Aziz, Ali↗
NASA NTRS2012

Transient Side Load Analysis of Out-of-Round Film-Cooled Nozzle Extensions

There was interest in understanding the impact of out-of-round nozzle extension on the nozzle side load during transient startup operations. The out-of-round nozzle extension could be the result of asymmetric internal stresses, deformation induced by previous tests, and asymmetric loads induced by hardware attached to the nozzle. The objective of this study was therefore to computationally investigate the effect of out-of-round nozzle extension on the nozzle side loads during an engine startup transient. The rocket engine studied encompasses a regeneratively cooled chamber and nozzle, along with a film cooled nozzle extension. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and transient inlet boundary flow properties derived from an engine system simulation. Six three-dimensional cases were performed with the out-of-roundness achieved by three different degrees of ovalization, elongated on lateral y and z axes: one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation line jump was the primary source of the peak side loads. Comparing to the peak side load of the perfectly round nozzle, the peak side loads increased for the slightly and more ovalized nozzle extensions, and either increased or decreased for the two significantly ovalized nozzle extensions. A theory based on the counteraction of the flow destabilizing effect of an exacerbated asymmetrical flow caused by a lower degree of ovalization, and the flow stabilizing effect of a more symmetrical flow, created also by ovalization, is presented to explain the observations obtained in this effort.

Wang, Ten-See↗
NASA NTRS1988

Short-crack growth behaviour in an aluminum alloy: An AGARD cooperative test program

An AGARD Cooperative Test Program on the growth of short fatigue cracks was conducted to define the significance of the short-crack effect, to compare test results from various laboratories, and to evaluate an existing analytical crack-growth prediction model. The initiation and growth of short fatigue cracks (5 micrometer to 2 mm) from the surface of a semi-circular notch in 2024-T3 aluminum alloy sheet material were monitored under various load histories. The cracks initiated from inclusion particle clusters or voids on the notch surface and generally grew as surface cracks. Tests were conducted under several constant-amplitude (stress ratios of -2, -1, 0, and 0.5) and spectrum (FALSTAFF and Gaussian) loading conditions at 3 stress levels each. Short crack growth was recorded using a plastic-replica technique. Over 250 edge-notched specimens were fatigue tested and nearly 950 cracks monitored by 12 participants from 9 countries. Long crack-growth rate data for cracks greater than 2 mm in length were obtained over a wide range in rates (10 to the -8 to 10 to the -1 mm/cycle) for all constant-amplitude loading conditions. Long crack-growth rate data for the FALSTAFF and Gaussian load sequences were also obtained.

Newman, J. C., Jr.↗