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At least 1,351 records · Page 75

All sources NASA NTRS DOE OSTI

NASA NTRS1994

Thermal Testing of High Performance: Thermal Barrier Coatings for Turbine Blades

A 350 micron thick 7 wt.% Y 2 O 3 -ZrO 2 (7YSZ) ceramic Thermal Barrier Coating (TBC) was manufactured in an argon atmosphere and with a strictly controlled substrate temperature on flat IN 600 samples and on IN 100 aircraft turbine blades. This new atmosphere and temperature controlled spraying (ATCS) allows the reduction of the residual stresses and an improvement in the microstructure and in the mechanical properties of the coating. The good performance of these new TBC's was assessed in thermal fatigue and in thermal shock tests carried out in air at 1100°C and at 1280°C respectively. The oxidation rate of the metal-ceramic interface was measured at 1100°C. Failure of the TBC's was induced only by the deterioration (like oxidation, cracking, ...) of the uncoated parts of the samples, as testing temperature was too severe for the base metals. Spalling was thereafter driven by compressive stresses near the aluminum oxide layer at the metal-ceramic interface. The results of these tests underline the good quality of the ceramic coating manufactured by the new ATCS technology.

L Bertamini↗

DOE OSTI2022

Cracking Behavior of Irradiated Ex-Plant Materials

The cracking behavior of reactor core internal materials is a key factor for the long-term safety and availability of light water reactors. Subject to high-temperature coolant, thermal and mechanical loading, and neutron irradiation, reactor core internal materials are susceptible to several degradation mechanisms during power operation. To understand the long-term effects of neutron irradiation, irradiated materials harvested from a decommissioned reactor were studied for their cracking susceptibility and fracture resistance. Small compact-tension specimens were machined from different locations on the baffle plates with irradiation doses ranging from 0.06 to 48.5 dpa. Crack growth rate and fracture toughness J-resistance (J-R) curve tests were performed on these specimens in a simulated light water reactor environment, and the fracture morphologies of the tested samples were examined with a scanning electron microscope. All samples behaved similarly under cyclic loading, and no deteriorated corrosion-fatigue behavior was observed in the test environments. Under constant load, no elevated cracking susceptibility was observed either in these samples at low stress intensity factors. However, a rapid cracking behavior featuring very high crack growth rates was observed in several high-dose samples. This rapid crack growth behavior was activated when the applied stress intensity factor, K, was sufficiently high. Once activated, the rapid crack growth remained steady even when the K was lowered to the pre-activation level and stopped only when the K was reduced drastically. Yet, the rapid crack growth could be re-activated repeatedly in these samples by raising the K above the initial activation level. This rapid cracking response may be related to the severe irradiation embrittlement experienced by these samples. The J-R curve tests performed with these samples showed a significant decline in fracture toughness with increasing neutron irradiation. Local cracking at the crack tip facilitated by the severe irradiation embrittlement of this material may be responsible for the rapid crack growth behavior demonstrated by this decommissioned material.

36 MATERIALS SCIENCE↗

NASA NTRS1986

Effects of geometry and materials on low cycle fatigue life of turbine blades in LOX/hydrogen rocket engines

This paper presents the results of an advanced turbine blade test program aimed at improving turbine blade low cycle fatigue (LCF) life. A total of 21 blades were tested in a blade thermal tester. The blades were made of MAR-M-246(Hf)DS and PWA-1480SC in six different geometries. The test results show that the PWA-1480SC material improved life by a factor of 1.7 to 3.0 over the current MAR-M-246(Hf)DS. The geometry changes yielded life improvements as high as 20 times the baseline blade made of PWA-1480SC and 34 times the baseline MAR-M-246DS blade.

Ryan, R. M.↗

DOE OSTI2022

Strain energy-based fatigue failure analyses of LB-PBF Inconel 718: Effect of build orientation

Additively manufactured Inconel 718 parts fabricated in three build orientations (horizontal, vertical, and angled at 45 degrees) are tested in fully-reversed bending fatigue mode. Damping measurements via the Impulse Excitation technique are used to assess the defects content in the microstructure and fractography analysis is performed to detect the root cause of failure. Two micro- and macro-scale methodologies of fatigue damage estimation based on the dissipated heat per cycle and the statistical estimation of micro-plastic strain energies are used to assess fatigue damage. It is shown that at a given stress level, the vertically built specimens endure the most fatigue damage before failure while the diagonally built ones sustain the least. As a result, the fatigue life is estimated for arbitrary load amplitudes via a microstructure-sensitive algorithm with acceptable accuracy as compared to the experiments.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Fatigue crack growth study of SCS6/Ti-15-3 composite

A study was performed to determine the fatigue crack growth (FCG) behavior and the associated fatigue damage processes in a (0)(8) and (90)(8) oriented SCS(6)/Ti-15-3 composite. Companion testing (CT) was also done on identically processed Ti-15-3 unreinforced material. The active fatigue crack growth failure processes were very similar for both composite orientations tested. For both orientations, fatigue crack growth was along the fiber direction. It was found that the composite constituent most susceptible to fatigue damage was the interface region and in particular the carbon coating surrounding the fiber. The failure of the interface region lead to crack initiation and also strongly influenced the FCG behavior in this composite. The failure of the interface region was apparently driven by normal stresses perpendicular to the fiber direction. The FCG rates were considerably higher for the (90)(8) oriented CT specimens in comparison to the unreinforced material. This is consistent with the scenario in which the interface has lower fatigue resistance than the matrix, causing lower composite fatigue resistance. The FCG rates of the (0)(8) composite could not be directly compared to the (90)(8) composite but were shown to increase with an increase in the crack length.

Kantzos, Peter↗

NASA NTRS1980

Statistical fatigue of unnotched composite laminates

A general analytical, phenomenological model is developed for characterizing fatigue damage accumulation in unnotched composite laminates, and experimental results are used to evaluate the model. The fatigue model, which is developed for various types of cyclic loadings, is based on the assumption that the residual strength reduction is a monotonically decreasing function of the fatigue life. Parameters are determined from baseline test data consisting of one set of residual strength data, one set of static strength data, and one set of constant amplitude fatigue life data. Once the parameters are determined, the model is able to predict: (1) the statistical distribution of the fatigue life, and the residual strength under constant and variable amplitude loads, and (2) the effect of periodic proof tests, without any additional experimental data. Experimental test results show that predictions made from the present model agree quite well with the experimental results. The model is also applicable to fatigue of bonded or bolted composite joints.

Yang, J. N.↗

NASA NTRS1985

Variables controlling fatigue crack growth of short cracks

A study was conducted to evaluate the roles of crack closure and microstructure in the fatigue growth of short cracks. Testing was performed at R ratios of 0.1, 0.5, and 0.7. At all R ratios short cracks exhibited accelerated growth rates in comparison to long cracks. It was concluded that crack closure could not entirely account for the accelerated growth rates of short cracks. The accelerated growth rates occurred over crack lengths on the order of grain size, suggesting a strong influence of microstructure. A significant effect of grain boundaries and inclusions on short crack FCG behavior was observed. For very short crack lengths, fatigue growth rates do not appear to be a function of either delta K or R ratio.

Telesman, J.↗

NASA NTRS1989

The high temperature deformation in cyclic loading of a single crystal nickel-base superalloy

The high temperature cyclic stress softening response of the single crystal nickel-base superalloy PWA 1480 was investigated. Specimens oriented near the 001- and 111-lines were tested at 1050 C in low-cycle fatigue and then microstructurally evaluated. The 001- and 111-line specimens had dissimilar flow behavior in monotonic tensile tests, but comparable softening in low-cycle fatigue. This softening was accompanied by rapid generation of dislocation networks at the gamma-gamma-prime interfaces and by a slower time-dependent coarsening of gamma-prime precipitates. Due to the rapid formation of a dislocation substructure at the gamma-gamma-prime interfaces, the cyclic stress softening could be modeled with an existing theory which related cyclic stress to the evolving microstructure and dislocation structure.

Gabb, T. P.↗

NASA NTRS1973

Evaluation of Stress Corrosion Cracking Susceptibility Using Fracture Mechanics Techniques, Part 1

Stress corrosion cracking (SSC) tests were performed on 13 aluminum alloys, 13 precipitation hardening stainless steels, and two titanium 6Al-4V alloy forgings to compare fracture mechanics techniques with the conventional smooth specimen procedures. Commercially fabricated plate and rolled or forged bars 2 to 2.5-in. thick were tested. Exposures were conducted outdoors in a seacoast atmosphere and in an inland industrial atmosphere to relate the accelerated tests with service type environments. With the fracture mechanics technique tests were made chiefly on bolt loaded fatigue precracked compact tension specimens of the type used for plane-strain fracture toughness tests. Additional tests of the aluminum alloy were performed on ring loaded compact tension specimens and on bolt loaded double cantilever beams. For the smooth specimen procedure 0.125-in. dia. tensile specimens were loaded axially in constant deformation type frames. For both aluminum and steel alloys comparative SCC growth rates obtained from tests of precracked specimens provide an additional useful characterization of the SCC behavior of an alloy.

Sprowls, D. O.↗

NASA NTRS1985

Fiberglass epoxy laminate fatigue properties at 300 and 20 K

A subcritical liquid hydrogen orbital storage and supply experiment is being designed for flight in the Space Shuttle cargo bay. The Cryogenic Fluid Management Experiment (CFME) includes a liquid hydrogen tank supported in a vacuum jacket by two fiberglass epoxy composite trunnion mounts. The ability of the CFME to last for the required seven missions depends primarily on the fatigue life of the composite trunnions at cryogenic temperatures. To verify the trunnion design and test the performance of the composite material, fatigue property data at 300 and 20 K were obtained for the specific E-glass fabric/S-glass unidirectional laminate that will be used for the CFME trunnions. The fatigue life of this laminate was greater at 20 K than at 300 K, and was satisfactory for the intended application.

Toth, J. M., Jr.↗

DOE OSTI2020

Crack Growth Rate and Fracture Toughness Tests on Irradiated Ex-Plant Materials

The performance of structural materials is critical for the safe and economic operation of light water reactors. Exposed to neutron irradiation during service, the reactor core internal materials can undergo significant microstructural and microchemical changes, leading to irradiation hardening and embrittlement. To ensure the structural integrity and functionality of nuclear reactor components during long-term operation, material degradation and damage mechanisms must be understood and managed adequately. In this work, irradiated materials harvested from the decommissioned Zorita reactor were studied for their cracking susceptibility and fracture resistance as a function of irradiation dose up to 47 displacement per atom (dpa). The material is a Type 304 stainless steel sectioned from the baffle plates of this pressurized water reactor with 38 years of service. Crack growth rate and fracture toughness J-resistance (J-R) curve tests were performed in low-corrosion-potential environments at ~315°C. All samples behaved similarly under cyclic loading, and no deteriorated corrosion-fatigue behavior was observed in the test environments. Under constant stress intensity factors, most samples did not show elevated crack growth rates, suggesting an adequate stress corrosion cracking resistance in the test environments. However, an unstable cracking behavior was observed in a 47-dpa sample, resulting in significantly higher crack growth rates than expected at high stress intensity factors. Crack instability was also observed in a 0.06-dpa sample but did not lead to a sustained high crack growth rate. The impact of neutron irradiation was more evident in the fracture toughness J-R curve tests. As the dose increased, the J-R curve declined considerably and became very shallow at high doses. A fully intergranular fracture morphology was also observed among the high-dose samples ruptured in an air atmosphere at room temperature. This brittle fracture mode in the absence of high temperature water environment confirmed a high degree of embrittlement of this material resulting from its service exposure to neutron irradiation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1993

Proposed framework for thermomechanical life modeling of metal matrix composites

The framework of a mechanics of materials model is proposed for thermomechanical fatigue (TMF) life prediction of unidirectional, continuous-fiber metal matrix composites (MMC's). Axially loaded MMC test samples are analyzed as structural components whose fatigue lives are governed by local stress-strain conditions resulting from combined interactions of the matrix, interfacial layer, and fiber constituents. The metallic matrix is identified as the vehicle for tracking fatigue crack initiation and propagation. The proposed framework has three major elements. First, TMF flow and failure characteristics of in situ matrix material are approximated from tests of unreinforced matrix material, and matrix TMF life prediction equations are numerically calibrated. The macrocrack initiation fatigue life of the matrix material is divided into microcrack initiation and microcrack propagation phases. Second, the influencing factors created by the presence of fibers and interfaces are analyzed, characterized, and documented in equation form. Some of the influences act on the microcrack initiation portion of the matrix fatigue life, others on the microcrack propagation life, while some affect both. Influencing factors include coefficient of thermal expansion mismatch strains, residual (mean) stresses, multiaxial stress states, off-axis fibers, internal stress concentrations, multiple initiation sites, nonuniform fiber spacing, fiber debonding, interfacial layers and cracking, fractured fibers, fiber deflections of crack fronts, fiber bridging of matrix cracks, and internal oxidation along internal interfaces. Equations exist for some, but not all, of the currently identified influencing factors. The third element is the inclusion of overriding influences such as maximum tensile strain limits of brittle fibers that could cause local fractures and ensuing catastrophic failure of surrounding matrix material. Some experimental data exist for assessing the plausibility of the proposed framework.

Halford, Gary R.↗

NASA NTRS2017

Fatigue Life and Damage Tolerance of Postbuckled Composite Stiffened Structures with Indentation Damage

The fatigue life and damage tolerance of composite stiffened panels with indentation damage are investigated experimentally using single-stringer compression specimens. The indentation damage was induced to one of the two flanges of the stringer of every panel. The advantages of indentation compared to impact are the simplicity of application, less dependence on boundary conditions, better controllability, and repeatability of the imparted damage. The tests were conducted using advanced instrumentation, including digital image correlation, passive thermography, and in situ ultrasonic scanning. Specimens with initial indentation damage ranging between 32 and 56 mm in length were tested quasi-statically and in fatigue, and the effects of cyclic load amplitude and damage size were studied. A means of comparison of the damage propagation rates and collapse loads based on a stress intensity measure and the Paris law is proposed. The stress intensity measure provides the means to compare the collapse loads of specimens with different damage types and damage sizes, while the Paris law is used to compare the damage propagation rates in specimens subjected to different cyclic loads. This approach enables a comparison of different tests and the potential identification of the effects that influence the fatigue lives and damage tolerance of postbuckled structures with defects.

Davila, Carlos G.↗

NASA NTRS1975

The detection of tightly closed flaws by nondestructive testing (NDT) methods

Liquid penetrant, ultrasonic, eddy current and X-radiographic techniques were optimized and applied to the evaluation of 2219-T87 aluminum alloy test specimens in integrally stiffened panel, and weld panel configurations. Fatigue cracks in integrally stiffened panels, lack-of-fusion in weld panels, and fatigue cracks in weld panels were the flaw types used for evaluation. A 2319 aluminum alloy weld filler rod was used for all welding to produce the test specimens. Forty seven integrally stiffened panels containing a total of 146 fatigue cracks, ninety three lack-of-penetration (LOP) specimens containing a total of 239 LOP flaws, and one-hundred seventeen welded specimens containing a total of 293 fatigue cracks were evaluated. Nondestructive test detection reliability enhancement was evaluated during separate inspection sequences in the specimens in the 'as-machined or as-welded', post etched and post proof loaded conditions. Results of the nondestructive test evaluations were compared to the actual flaw size obtained by measurement of the fracture specimens after completing all inspection sequences. Inspection data were then analyzed to provide a statistical basis for determining the flaw detection reliability.

Rummel, W. D.↗

NASA NTRS1988

Characterization of Mode 1 and Mode 2 delamination growth and thresholds in graphite/peek composites

Composite materials often fail by delamination. The onset and growth of delamination in AS4/PEEK, a tough thermoplastic matrix composite, was characterized for mode 1 and mode 2 loadings, using the Double Cantilever Beam (DCB) and the End Notched Flexure (ENF) test specimens. Delamination growth per fatigue cycle, da/dN, was related to strain energy release rate, G, by means of a power law. However, the exponents of these power laws were too large for them to be adequately used as a life prediction tool. A small error in the estimated applied loads could lead to large errors in the delamination growth rates. Hence strain energy release rate thresholds, G sub th, below which no delamination would occur were also measured. Mode 1 and 2 threshold G values for no delamination growth were found by monitoring the number of cycles to delamination onset in the DCB and ENF specimens. The maximum applied G for which no delamination growth had occurred until at least 1,000,000 cycles was considered the threshold strain energy release rate. Comments are given on how testing effects, facial interference or delamination front damage, may invalidate the experimental determination of the constants in the expression.

Martin, Roderick H.↗

NASA NTRS1990

Characterization of Mode I and Mode II delamination growth and thresholds in AS4/PEEK composites

Martin, Roderick H.↗

NASA NTRS1982

Mechanical properties of a fiberglass prepreg system at cryogenic and other temperatures

The compressor driving the flow in the National Transonic Facility, which is nearing completion at the Langley Research Center, has 25 fiberglass blades. E-glass cloth with a pre-impregnated epoxy resin has been selected as the material for the fan blades because of its low cost, high damping, and fatigue resistance. A complete characterization is presented of this fan blade fiberglass system at temperatures of 367 K, room temperature, and 89 K. The characterization test results suggest that the material follows the general trends of metals and other glass-reinforced plastics at cryogenic temperatures. A slight diminution in strength was observed at the elevated temperature. The tests included the following: tensile, compression, fatigue, inplane shear, interlaminar shear, thermal expansion, creep, and thermal cycle.

Klich, P. J.↗

NASA NTRS1993

(abstract) A Brief, Selective Review of Thermal Cycling Fatigue in Eutectic Tin-Lead Solder

This paper reviews selected parts of the current literature relevant to thermo-mechanical fatigue mechanisms in eutectic tin-lead solder, and suggests a general outline to account for some observed failures. The field is found to be complex. One recent experimental study finds some failure modes to be sensitive to joint geometry. Attempts to extrapolate from test environments to service environments have had only limited success. Much work remains to be done before fatigue failures in this material can be considered as under practical control.

environments↗