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In production of tractor and a line of farm vehicles, Deere and Company used a COSMIC computer program called FEATS for Finite Element Analysis of Thermal Stress in computer analysis of diesel engine pistons, connecting rods and rocker arms. Company reports that use of FEATS afforded considerable savings and improved analytical accuracies, process efficiencies and product reliability.
Furnace brazing is a joining process used in the aerospace and other industries to produce strong permanent and hermetic structural joints. As in any joining process, brazed joints have various imperfections and defects. At the present time, our understanding of the influence of the internal defects on the strength of the brazed joints is not adequate. The goal of this 3-part investigation is to better understand the properties and failure mechanisms of the brazed joints containing defects. This study focuses on the behavior of the brazed lap shear joints because of their importance in manufacturing aerospace structures. In Part 1, an average shear strength capability and failure modes of the single lap joints are explored. Stainless steel specimens brazed with pure silver are tested in accordance with the AWS C3.2 standard. Comparison of the failure loads and the ultimate shear strength with the Finite Element Analysis (FEA) of the same specimens as a function of the overlap widths shows excellent correlation between the experimental and calculated values for the defect-free lap joints. A damage zone criterion is shown to work quite well in understanding the failure of the braze joints. In Part 2, the findings of the Part 1 will be verified on the larger test specimens. Also, various flaws will be introduced in the test specimens to simulate lack of braze coverage in the lap joints. Mechanical testing and FEA will be performed on these joints to verify that behavior of the flawed ductile lap joints is similar to joints with a reduced braze area. Finally, in Part 3, the results obtained in Parts 1 and 2 will be applied to the actual brazed structure to evaluate the load-carrying capability of a structural lap joint containing discontinuities. In addition, a simplified engineering procedure will be offered for the laboratory testing of the lap shear specimens.
This paper presents results of the second part of an on-going effort to gain better understanding of defect tolerance in braze joints. In the first part of this three-part series, we mechanically tested and modeled the strength of the lap joints as a function of the overlap distance. A failure criterion was established based on the zone damage theory, which predicts the dependence of the lap joint shear strength on the overlap distance, based on the critical size of a finite damage zone or an overloaded region in the joint. In this second part of the study, we experimentally verified the applicability of the damage zone criterion on prediction of the shear strength of the lap joint and introduced controlled flaws into the lap joints. The purpose of the study was to evaluate the lap joint strength as a function of flaw size and its location through mechanical testing and nonlinear finite element analysis (FEA) employing damage zone criterion for definition of failure. The results obtained from the second part of the investigation confirmed that the failure of the ductile lap shear brazed joints occurs when the damage zone reaches approximately 10% of the overlap width. The same failure criterion was applicable to the lap joints containing flaws.
This paper presents a parameter study of the effect of boom axial loading on the global dynamics of a 2-meter solar sail scale model. The experimental model used is meant for building expertise in finite element analysis and experimental execution, not as a predecessor to any planned flight mission or particular design concept. The results here are to demonstrate the ability to predict and measure structural dynamics and mode shapes in the presence of axial loading.
The Microgravity Emissions Laboratory (MEL) was developed at the NASA Glenn Research Center for the characterization, simulation, and verification of the International Space Station (ISS) microgravity environment. This Glenn lab was developed in support of the Fluids and Combustion Facility (FCF). The MEL is a six-degrees-of-freedom inertial measurement system that can characterize the inertial response forces (emissions) of components, subrack payloads, or rack-level payloads down to 10 7g. The inertial force output data generated from the steady-state or transient operations of the test article are used with finite element analysis, statistical energy analysis, and other analysis tools to predict the on-orbit environment at specific science or rack interface locations. Customers of the MEL have used benefits in isolation performance testing in defining available attenuation during the engineering hardware design phase of their experiment s development. The Light Microscopy Module (LMM) Control Box (LCB) fan was tested in the MEL in June and July of 2002. The LMM is planned as a remotely controllable on-orbit microscope subrack facility that will be accommodated in an FCF Fluids Integrated Rack on the ISS. The disturbances measured in the MEL test resulted from operation of the air-circulation fan within the LCB. The objectives of the testing were (1) to identify an isolator to be added to the LCB fan assembly to reduce fan-speed harmonics and (2) to identify the fan-disturbance forcing functions for use in rack-response analysis of the LMM and Fluids Integrated Rack facility. This report describes the MEL, the testing process, and the results from ground-based MEL LCB fan testing.
Fatigue crack growth rate testing is performed by automated data collection systems that assume straight crack growth in the plane of symmetry and use standard polynomial solutions to compute crack length and stress-intensity factors from compliance or potential drop measurements. Visual measurements used to correct the collected data typically include only the horizontal crack length, which for cracks that propagate out-of-plane, under-estimates the crack growth rates and over-estimates the stress-intensity factors. The authors have devised an approach for correcting both the crack growth rates and stress-intensity factors based on two-dimensional mixed mode-I/II finite element analysis (FEA). The approach is used to correct out-of-plane data for 7050-T7451 and 2025-T6 aluminum alloys. Results indicate the correction process works well for high DeltaK levels but fails to capture the mixed-mode effects at DeltaK levels approaching threshold (da/dN approximately 10(exp -10) meter/cycle).
Elevated temperature burst testing of a disk with a dual grain structure made from an advanced nickel-base superalloy, LSHR, was conducted. The disk had a fine grain bore and coarse grain rim, produced using NASA's low cost DMHT technology. The results of the spin testing showed the disk burst at 42 530 rpm in line with predictions based on a 2-D finite element analysis. Further, significant growth of the disk was observed before failure which was also in line with predictions.
Uncontained engine failures, although rare in occurrence, can have a catastrophic effect on aircraft performance and safety. Engine disk cracks can eventually lead to these type of failures. A number of techniques to detect engine disk cracks have been developed in recent years. However, these technologies have only been validated by disk spin pit tests, not actual engine tests. Due to this, a project was established to perform seeded fault engine tests on a TF41 engine disk fan. A defect was machined in the first stage fan disk of a TF41 engine. The disk was run in a spin pit to initiate a crack. Once initiated, the disk was run in an actual engine test facility. The engine was cycled by a number of start and stops with the goal of propagating the crack to disk burst through low cycle fatigue. Various crack detection techniques were installed on the engine and run real-time during the test to validate their abilities to detect disk cracks. These techniques were based on methods such as change in mass imbalance using vibration or shaft displacement, change in blade position, acoustic emission, and torsional resonance. At the completion of 4474 test cycles, the crack in the TF41 disk was determined to have grown approximately 0.025 inches. This was far less the predicted crack growth based on a fracture mechanics analysis and finite element stress analysis.
New high temperature low power 8-pin packages have been fabricated using commercial fabrication service. These packages are made of aluminum nitride and 96 percent alumina with Au metallization. The new design of these packages provides the chips inside with EM shielding. Wirebond geometry control has been achieved for precise mechanical tests. Au wirebond samples with 45 degree heel-angle have been tested using wireloop test module. The geometry control improves the consistency of measurement of the wireloop breaking point.Also reported on is a parametric study of the thermomechanical reliability of a Au thick-film based SiC die-attach assembly using nonlinear finite element analysis (FEA) was conducted to optimize the die-attach thermo-mechanical performance for operation at temperatures from room temperature to 500 degrees Centigrade. This parametric study centered on material selection, structure design and process control.
A study is presented using photogrammetry to measure the biaxial strain in an inflated cylinder. Two cylinders constructed from polyethylene and each approximately 222 mm in diameter and 930 mm in length were studied. The first had a 0.038 mm wall thickness while the second had a 0.02 mm wall thickness. The cylinders were inflated to a maximum pressure of 1379 Pa. The strain was determined from data collected from 60 retro-reflective targets arranged in a 12 x 5 grid. The uncertainty of the measurement system was determined to be 0.08, 0.04 and 0.06 mm in the x, y, and z directions respectively. The hoop and meridional strains determined from displacement data were compared to values obtained from a finite element analysis of a related proxy problem. The predicted hoop strains showed good agreement over the entire range of pressures while the meridional strains showed good agreement at the lower pressures.
The analytical approach used to develop a novel fatigue crack growth coupon for highly plastic stress field condition is presented in this paper. The flight hardware investigated is a large separation bolt that has a deep notch, which produces a large plastic zone at the notch root when highly loaded. Four test specimen configurations are analyzed in an attempt to match the elastic-plastic stress field and crack constraint conditions present in the separation bolt. Elastic-plastic finite element analysis is used to compare the stress fields and critical fracture parameters. Of the four test specimens analyzed, the modified double-edge notch tension - 3 (MDENT-3) most closely approximates the stress field, J values, and crack constraint conditions found in the flight hardware. The MDENT-3 is also most insensitive to load misalignment and/or load redistribution during crack growth.
A parametric study of the effects of test-fixture-induced initial prestress and elastic edge restraints on the prebuckling and buckling responses of a compression-loaded, quasi-isotropic curved panel is presented. The numerical results were obtained by using a geometrically nonlinear finite element analysis code with high-fidelity models. The results presented show that a wide range of prebuckling and buckling behavior can be obtained by varying parameters that represent circumferential loaded-edge restraint and rotational unloaded-edge restraint provided by a test fixture and that represent the mismatch in specimen and test-fixture radii of curvature. For a certain range of parameters, the panels exhibit substantial nonlinear prebuckling deformations that yield buckling loads nearly twice the corresponding buckling load predicted by a traditional linear bifurcation buckling analysis for shallow curved panels. In contrast, the results show another range of parameters exist for which the nonlinear prebuckling deformations either do not exist or are relatively benign, and the panels exhibit buckling loads that are nearly equal to the corresponding linear bifurcation buckling load. Overall, the results should also be of particular interest to scientists, engineers, and designers involved in simulating flight-hardware boundary conditions in structural verification and certification tests, involved in validating structural analysis tools, and interested in tailoring buckling performance.
Single crystal superalloy turbine blades used in high pressure turbomachinery are subject to conditions of high temperature, triaxial steady and alternating stresses, fretting stresses in the blade attachment and damper contact locations, and exposure to high-pressure hydrogen. The blades are also subjected to extreme variations in temperature during start-up and shutdown transients. The most prevalent HCF failure modes observed in these blades during operation include crystallographic crack initiation/propagation on octahedral planes, and noncrystallographic initiation with crystallographic growth. Numerous cases of crack initiation and crack propagation at the blade leading edge tip, blade attachment regions, and damper contact locations have been documented. Understanding crack initiation/propagation under mixed-mode loading conditions is critical for establishing a systematic procedure for evaluating HCF life of single crystal turbine blades. This paper presents analytical and numerical techniques for evaluating two and three dimensional subsurface stress fields in anisotropic contacts. The subsurface stress results are required for evaluating contact fatigue life at damper contacts and dovetail attachment regions in single crystal nickel-base superalloy turbine blades. An analytical procedure is , presented, for evaluating the subsurface stresses in the elastic half-space, using a complex potential method outlined by Lekhnitskii. Numerical results are presented for cylindrical and spherical anisotropic contacts, using finite element analysis. Effects of crystal orientation on stress response and fatigue life are examined.
The effect of changing operating temperature on the compressive response of IM7/PETI5 composite laminates is investigated within this paper. The three temperatures evaluated for this study were 129 C, 21 C, and 177 C, a spectrum from cryogenic to an elevated operating temperature. Laminate compressive strength property testing was conducted using the Wyoming Combined Load Compression fixture to generate strength data at the three operating temperatures of interest for several lay-ups. A three-dimensional finite element analysis model of a [90/0]8s composite laminate subject to compressive loading is developed. The model is used to study the key attributes of the laminate that significantly influence the state of stress in the laminate. Both the resin rich layer located between lamina and the thermal residual stresses present in the laminate due to curing are included in the analysis model. For the laminate modeled, the effect of modeling temperature dependent material properties was determined to be insignificant for the operating temperatures studied. Simply using the material properties measured at the operating temperature of interest was sufficient for predicting stresses accurately in a linear analysis for the current problem. The three-dimensional analysis results revealed that the application of an applied compressive axial load in the 0-degree direction decreased the interlaminar stresses present in the laminate initially due to curing. Therefore, failure was concluded not be attributable to the interlaminar stresses in the composite laminate being studied when a compressive load is applied. The magnitude of the measured laminate compressive strength change with a change in temperature is concluded to be dominated by the change in the lamina compressive axial strength with a change in temperature.
An experimental and analytical evaluation of the compressive response of two notched composite stiffened panels representative of primary composite wing structure is presented. A three-dimensional full-field image correlation technique is used to measure the three displacement components over global and local areas of the test panels. Full-field displacement results obtained using the image correlation technique are presented and compared to experimental results and analytical results obtained using nonlinear finite element analysis. Both global and global-local image correlation results are presented and discussed.
The inverse problem of real-time reconstruction of full-field structural displacements is addressed through the application of a new variational formulation leading to versatile, robust and computationally efficient inverse shell finite element analysis. Utilizing surface strain measurements from strain sensors mounted on the load-carrying structural components, the methodology enables accurate computations of the three-dimensional displacement field. This high fidelity computational technology is essential for providing feedback to the actuation and control systems of the next generation of aerospace vehicles.
Results of a numerical parametric study of the prebuckling and postbuckling response of tailored composite stiffened panels with axial-shear coupling are presented. In the stiffened panels, axial-shear stiffness coupling is created by rotating the stiffener orientation and tailoring the skin laminate anisotropy. The panels are loaded in axial compression and the effects of stiffener orientation and skin anisotropy on the panel stiffness, buckling parameters, and axial-shear coupling response are described. Results are obtained from a nonlinear general shell finite element analysis computer code. The prebuckling and postbuckling responses can be affected by both the stiffener orientation and skin laminate anisotropy, and the effects are different and load dependent. The results help identify different mechanisms for axial-shear coupling, and show that a load-dependent structural response can be controlled by selecting appropriate stiffener and skin parameters.
An experimental and analytical evaluation of the compressive response of two composite, notched stiffened panels representative of primary composite wing structure is presented. A three-dimensional full-field image correlation technique is used to measure all three displacement components over global and local areas of the test panels. Point-wise and full-field results obtained using the image correlation technique are presented and compared to experimental results and analytical results obtained using nonlinear finite element analysis. Both global and global-local image correlation results are presented and discussed. Results of a simple calibration test of this image correlation technique are also presented.