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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 1,369 records · Page 76
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Analytical Modelling of Transverse Matrix Cracking of [plus or minus Theta/90(sub n)](sub s) Composite Laminates Under Multiaxial Loading

An analytical model based on the analysis of a cracked unit cell of a composite laminate subjected to multiaxial loads is proposed to predict the onset and accumulation of transverse matrix cracks in the 90(sub n) plies of uniformly stressed [plus or minus Theta/90(sub n)](sub s) laminates. The model predicts the effect of matrix cracks on the stiffness of the laminate, as well as the ultimate failure of the laminate, and it accounts for the effect of the ply thickness on the ply strength. Several examples describing the predictions of laminate response, from damage onset up to final failure under both uniaxial and multiaxial loads, are presented.

Mayugo, J A.↗
NASA NTRS2010

Experimental Evaluation of Fatigue Crack Initiation from Corroded Hemispherical Notches in Aerospace Structural Materials

A test program was developed and executed to evaluate the influence of corroded hemispherical notches on the fatigue crack initiation and propagation in aluminum 7075-T7351, 4340 steel, and D6AC steel. Surface enhancements such as shot peening and laser shock peening were also incorporated as part of the test effort with the intent of improving fatigue performance. In addition to the testing, fracture mechanics and endurance limit based analysis methods were evaluated to characterize the results with the objective of challenging typical assumptions used in modeling fatigue cracks from corrosion pits. The results specifically demonstrate that the aluminum and steel alloys behave differently with respect to fatigue crack initiation from hemispherical corrosion pits. The aluminum test results were bounded by the fracture mechanics and endurance limit models while exhibiting a general insensitivity to the residual stress field generated by shot peening. The steel specimens were better characterized by the endurance limit fatigue properties and did exhibit sensitivities to residual stresses from the shot peening and laser shock peening

Garcia, Daniel B.↗
NASA NTRS2012

Implementation of a Smeared Crack Band Model in a Micromechanics Framework

The smeared crack band theory is implemented within the generalized method of cells and high-fidelity generalized method of cells micromechanics models to capture progressive failure within the constituents of a composite material while retaining objectivity with respect to the size of the discretization elements used in the model. An repeating unit cell containing 13 randomly arranged fibers is modeled and subjected to a combination of transverse tension/compression and transverse shear loading. The implementation is verified against experimental data (where available), and an equivalent finite element model utilizing the same implementation of the crack band theory. To evaluate the performance of the crack band theory within a repeating unit cell that is more amenable to a multiscale implementation, a single fiber is modeled with generalized method of cells and high-fidelity generalized method of cells using a relatively coarse subcell mesh which is subjected to the same loading scenarios as the multiple fiber repeating unit cell. The generalized method of cells and high-fidelity generalized method of cells models are validated against a very refined finite element model.

Pineda, Evan J.↗
NASA NTRS2013

Cohesive Modeling of Transverse Cracking in Laminates with a Single Layer of Elements per Ply

This study aims to bridge the gap between classical understanding of transverse cracking in cross-ply laminates and recent computational methods for the modeling of progressive laminate failure. Specifically, the study investigates under what conditions a finite element model with cohesive X-FEM cracks can reproduce the in situ effect for the ply strength. It is shown that it is possible to do so with a single element across the thickness of the ply, provided that the interface stiffness is properly selected. The optimal value for this interface stiffness is derived with an analytical shear lag model. It is also shown that, when the appropriate statistical variation of properties has been applied, models with a single element through the thickness of a ply can predict the density of transverse matrix cracks

VanDerMeer, Frans P.↗
NASA NTRS2014

Humidity Testing of PME and BME Ceramic Capacitors with Cracks

Cracks in ceramic capacitors are one of the major causes of failures during operation of electronic systems. Humidity testing has been successfully used for many years to verify the absence of cracks and assure quality of military grade capacitors. Traditionally, only precious metal electrode (PME) capacitors were used in high reliability applications and the existing requirements for humidity testing were developed for this type of parts. With the advance of base metal electrode (BME) capacitors, there is a need for assessment of the applicability of the existing techniques for the new technology capacitors. In this work, variety of different PME and BME capacitors with introduced cracks were tested in humid environments at different voltages and temperatures. Analysis of the test results indicates differences in the behavior and failure mechanisms for BME and PME capacitors and the need for different testing conditions.

reliability↗
NASA NTRS2013

Experimental Characterization and Simulation of Slip Transfer at Grain Boundaries and Microstructurally-Sensitive Crack Propagation

A systematic study of crack tip interaction with grain boundaries is critical for improvement of multiscale modeling of microstructurally-sensitive fatigue crack propagation and for the computationally-assisted design of more durable materials. In this study, single, bi- and large-grain multi-crystal specimens of an aluminum-copper alloy are fabricated, characterized using electron backscattered diffraction (EBSD), and deformed under tensile loading and nano-indentation. 2D image correlation (IC) in an environmental scanning electron microscope (ESEM) is used to measure displacements near crack tips, grain boundaries and within grain interiors. The role of grain boundaries on slip transfer is examined using nano-indentation in combination with high-resolution EBSD. The use of detailed IC and EBSD-based experiments are discussed as they relate to crystal-plasticity finite element (CPFE) model calibration and validation.

Gupta, Vipul↗
NASA NTRS2014

Mode I Cohesive Law Characterization of Through-Crack Propagation in a Multidirectional Laminate

A method is proposed and assessed for the experimental characterization of through-the-thickness crack propagation in multidirectional composite laminates with a cohesive law. The fracture toughness and crack opening displacement are measured and used to determine a cohesive law. Two methods of computing fracture toughness are assessed and compared. While previously proposed cohesive characterizations based on the R-curve exhibit size effects, the proposed approach results in a cohesive law that is a material property. The compact tension specimen configuration is used to propagate damage while load and full-field displacements are recorded. These measurements are used to compute the fracture toughness and crack opening displacement from which the cohesive law is characterized. The experimental results show that a steady-state fracture toughness is not reached. However, the proposed method extrapolates to steady-state and is demonstrated capable of predicting the structural behavior of geometrically-scaled specimens.

Bergan, Andrew C.↗
NASA NTRS1961

Spontaneous Cracking in Unfired Magnesia Compacts Upon Standing in Air

Analytical-grade magnesium oxide powder without binder was compressed hydrostatically to 50,000 lb. per sq. in. to form compacts. When exposed to moist air immediately after pressing, these compacts developed irregularly shaped cracks. Controlled tests, in which these compacts were exposed for various lengths of time to various atmospheres, indicated that in general water vapor, carbon dioxide, and residual stresses had to be present if cracking was to occur. The probable cause of the cracking was the formation of a less dense and mechanically weak basic carbonate of magnesium at crystallite surface points of high stress concentration which developed during the compacting. The adsorption of dry CO2 at such sites prevented subsequent delayed fracture.

Davies, Myron O.↗
NASA NTRS2016

Estimating Orion Heat Shield Failure Due To Ablator Cracking During The EFT-1 Mission

The Orion EFT-1 heatshield suffered from two major certification challenges: First, the mechanical properties used in design were not evident in the flight hardware and second, the flight article itself cracked during fabrication. The combination of these events motivated the Orion Program to pursue an engineering-level Probabilistic Risk Assessment (PRA) as part of heatshield certification rationale. The PRA provided loss of Mission (LOM) likelihoods considering the probability of a crack occurring during the mission and the likelihood of subsequent structure over-temperature. The methods and input data for the PRA are presented along with a discussion of the test data used to anchor the results. The Orion program accepted an EFT-1 Loss of Vehicle (LOV) risk of 1-in-160,000 due to in-mission Avcoat cracking based on the results of this analysis. Conservatisms in the result, along with future considerations for Exploration Missions (EM) are also addressed.

Avcoat↗
NASA NTRS2016

The Effects of Salt Water on the Slow Crack Growth of Soda Lime Silicate Glass

The slow crack growth parameters of soda-lime silicate were measured in distilled and salt water of various concentrations in order to determine if stress corrosion susceptibility is affected by the presence of salt and the contaminate formation of a weak sodium film. Past research indicates that solvents effect the rate of crack growth, however, the effects of salt have not been studied. The results indicate a small but statistically significant effect on the slow crack growth parameters A and n. However, for typical engineering purposes, the effect can be ignored.

Toughness↗
NASA NTRS2018

Combining Progressive Nodal Release with the Virtual Crack Closure Technique to Model Fatigue Delamination Growth Without Re-Meshing

The present work summarizes an approach to model mixed-mode 3D fatigue crack growth using the Virtual Crack Closure Technique (VCCT) without requiring re-meshing. It is demonstrated that the proposed approach can be used to simulate crack shapes that do not conform to the underlying mesh. The proposed approach relies solely on Paris Law characterization data to model delamination growth. Growth is determined as a post-processing step at the end of each increment, and hence no convergence issues associated with the progressive nodal release are encountered. This approach can be readily applied using standard solid element formulations and is implemented via an interface user element in Abaqus/Standard.

Carvalho, N. V. De↗
NASA NTRS2018

An Abrupt Transition to an Intergranular Failure Mode in the Near-Threshold Fatigue Crack Growth Regime in Ni-Based Superalloys

Cyclic near-threshold fatigue crack growth (FCG) behavior of two disk superalloys was evaluated and was shown to exhibit an unexpected sudden failure mode transition from a mostly transgranular failure mode at higher stress intensity factor ranges to an almost completely intergranular failure mode in the threshold regime. The change in failure modes was associated with a crossover of FCG resistance curves in which the conditions that produced higher FCG rates in the Paris regime resulted in lower FCG rates and increased Kth values in the threshold region. High-resolution scanning and transmission electron microscopy were used to carefully characterize the crack tips at these near-threshold conditions. Formation of stable Al-oxide followed by Cr-oxide and Ti-oxides was found to occur at the crack tip prior to formation of unstable oxides. To contrast with the threshold failure mode regime, a quantitative assessment of the role that the intergranular failure mode has on cyclic FCG behavior in the Paris regime was also performed. It was demonstrated that even a very limited intergranular failure content dominates the FCG response under mixed mode failure conditions.

Telesman, J.↗
NASA NTRS2018

Stress Corrosion Cracking of Metals in Propellants

Stress corrosion cracking (SCC) of a fracture critical metallic material can cause a premature failure if the material is susceptible in the unique service environment. Material fluid compatibility is an area of interest for the current NASA programs leading the human exploration path to Mars. White Sands Test Facility, the agency's lead on hypergolic propellant testing, identifies a lack in stress corrosion cracking susceptibility data for metallic materials in hypergolic propellants. The development of a stress corrosion cracking screening method is necessary to bridge the knowledge gap and enable the community to more confidently select materials for the use in systems containing corrosive fluids.

Alcantara, Ilse↗
NASA NTRS2018

Optical Measurement System for Strain Field Ahead of a Crack Tip for Lattice Structures

The aim of the ARAMADAS project is to automate the construction of cuboctahedral lattice structures. Lattice materials are appealing for aerospace applications due to their strength and stiffness at ultra-light densities. However, in order for any material to be realistically considered for such environments, it must also be damage tolerant. The ability of a material to absorb damage is characterized by its fracture toughness, which remains poorly characterized for lattice materials. Consequently, the objective of this research is to develop an optical measurement system to experimentally validate the strain field ahead of a crack tip in architecture lattice materials. Although the ability to predict the strain field ahead of a crack tip has been investigated for continuum materials, such behaviour of three-dimensional architectures is under-investigated. As such, we will use a custom optical measurement system to track deformation of the voxels in a side-cracked plate fracture specimen. The system shall use 3D pose estimation, stereo imaging, and possibly color tracking, in combination with optical flow algorithms, to compute information regarding the three-dimensional movement movement of the lattice nodes during mechanical testing. Bench top experiments will validate the optical measurement system and characterize precision. Additionally, the effect of multiple cameras on precision, as well as system scalability will be investigated. Final results will compare measured lattice deformation with finite element predictions.

Lennig, Miriam↗
NASA NTRS2019

Experimental Study on Mitigation of Lifetime-Limiting Dielectric Cracking in Extreme Temperature 4H-SiC JFET Integrated Circuits

While NASA Glenn Research Center's "Generation 10" 4H-SiC Junction Field Effect Transistor (JFET) integrated circuits (ICs) have uniquely demonstrated 500 °C electrical operation for durations of over a year, this experimental work has also revealed that physical cracking of chip dielectric passivation layers ultimately limits extreme-environment operating lifetime [1-3]. The prevention of such dielectric passivation cracks should therefore improve IC high temperature durability and yield, leading to more beneficial technology adoption into aerospace, automotive, and energy systems. This report describes Generation 10.2, 11.1, and 11.2 die tested under unbiased and unpackaged accelerated age testing at 500 °C, 600 °C, 720 °C, and 800 °C in air-atmosphere ovens for 100- and 200-hour duration. Additional samples were separately subjected to 10 thermal cycles between the same high temperatures (with 10-hour high-temperature soak each cycle) and 50 °C. It is shown that having two stoichiometric Si3N4 layers in the interconnect dielectric stack substantially decreases the amount of dielectric cracking observed following these oven tests.

Spry, D. J.↗
NASA NTRSDate not supplied

Weldability Investigation of Crack Resistant Aluminum Filler Metals Developed for Large Scale Additive Manufacturing and Industrial Welding Applications

In this study the NASA MSFC welding and manufacturing team investigated a new-age aluminum filler wire designed for welding and additive manufacturing (AM) of high strength aluminum alloys. High strength aluminum alloys are known to exhibit hot cracking and hot tearing issues during fusion welding operations. The goal of this investigation was to determine whether this new-age family of alloys can suppress the hot cracking and hot tearing issues exhibited during welding of high strength aluminum alloys and to do an initial characterization of the mechanical performance of welds created using these filler wires. This study focuses on fusion welding of aluminum alloy 6061 and compares the weldability characteristics of five aluminum filler metals and two forms of 6061 base material. The MSFC team utilized manual gas tungsten arc welding (GTAW) to conduct all welding operations and carried out metallographic analysis accompanied with mechanical testing to evaluate the performance of the welds created during this study. During the study it was observed that the new-age filler wires facilitated grain refinement in the weld fusion zone and were capable of creating crack free welds in aluminum alloy 6061 while exhibiting properties that met or exceeded conventional off the shelf aluminum filler metals.

Welding↗
DOE OSTI2020

Role of Material Condition in Precursor Corrosion Damage and Stress Corrosion Crack Initiation Behavior of Alloy 600 in PWR Primary Water

Stress corrosion crack (SCC) initiation testing has been performed on a 15% cold-worked UNS N06600 (Alloy 600) heat in the mill-annealed (MA), solution annealed (SA), and thermally treated (TT) conditions to assess the role of grain boundary (GB) carbides on stress-assisted intergranular attack (IGA) and short crack nucleation and growth. The SCC initiation tests were conducted at constant load equivalent to materials yield stress in 360oC simulated PWR primary water with dissolved hydrogen at the Ni/NiO stability line. Results revealed the highest SCC initiation susceptibility in the Alloy 600 MA material followed by the TT and SA materials, suggesting the GB carbide distribution did not have a controlling effect on SCC initiation resistance. Quantitative assessments were conducted on IGA and short cracks to help understand this phenomenon and the role of GB carbides on precursor damage development that lead to differences in macroscopic SCC initiation behavior are discussed.

Zhai, Ziqing↗
DOE OSTI2024

Complex Fluid‐Driven Fractures Caused by Crack‐Parallel Stress

Abstract Managing fluid‐driven fracture networks is crucial for subsurface resource utilization, yet the current understanding of the key controlling factors remains insufficient. While geologic discontinuities have been shown to significantly influence fracture network complexity, this study identifies another major contributor. We conducted a new set of experiments using a transparent true triaxial cell, which enabled video recording of the temporal evolution of fluid‐driven fracture paths. Using pseudo‐2D samples without macroscale structural discontinuities, we observed multiple occurrences of hydraulic fracture curving and branching under anisotropic boundary stresses. We proposed a theoretical model demonstrating that the stress parallel to the crack line in the solid matrix near the crack tip (i.e., the T ‐stress) accounts for the observed fracture curving behavior. This finding suggests that T ‐stress is an additional mechanism contributing to the complexity of fluid‐driven fracture networks in the subsurface, besides the geologic discontinuities.

58 GEOSCIENCES↗