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At least 1,495 records · Page 83
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Liftoff and Time Equivalent Duration Data Evaluation of Exploration Flight Test 1 Orion Multi-Purpose Crew Vehicle

The liftoff phase induces high acoustic loading over a broad frequency range for a launch vehicle. These external acoustic environments are used in the prediction of the internal vibration responses of the vehicle and components. There arises the question about time equivalent (Teq) duration of the liftoff phase and similarity to other launch vehicles. Vibroacoustic engineers require the fatigue-weighted time duration values for qualification testing inputs. In order to determine the Teq for the Space Launch System, NASA's newest launch vehicle, the external microphone data from the Exploration Flight Test 1 (EFT-1) flight of the Orion Multi-Purpose Crew Vehicle (MPCV) was evaluated. During that evaluation, a trend was observed in the data and the origin of that trend is discussed in this paper. Finally, the Teq values for the EFT-1 Orion MPCV are presented.

Houston, Janice↗
NASA NTRS1972

The influence of temperature on fatigue-crack growth in a mill annealed Ti-6Al-4V alloy

To understand the influence temperature on the rate of fatigue crack growth in high strength metal alloys, constant load amplitude, fatigue crack growth experiments were carried out using a 1/4-inch-thick (6.35 mm) mill annealed Ti-6Al-4V alloy plate as a model material. The rates of fatigue crack growth were determined as a function of temperature, ranging from room temperature to about 290 C (or, about 550 F/563K) and as a function of the crack tip stress intensity factor in a dehumidified high purity argon environment. Limited correlative experiments indicate that dehumidified oxygen and hydrogen have no effect on the rate of fatigue crack growth in this alloy, while distilled water increased the rate of crack growth slightly in the range tested. Companion fractographic examinations suggest that the mechanisms for fatigue crack growth in the various environments are essentially the same.

Wei, R. P.↗
NASA NTRS1984

Three-dimensional measurements of fatigue crack closure

Three dimensional fatigue crack opening profiles in transparent polymer test specimens were determined. The load required to separate crack faces was measured along the crack profile at various positions through the specimens thickness. Crack opening loads at the specimen surface (under plane stress conditions) were compared with measurements made under plane strain conditions the specimen interior. The fatigue crack opening load was correlated with fatigue crack retardation behavior caused by peak overloads, and the results discussed in terms of three dimensional aspects of the fatigue crack closure mechanism for fatigue crack retardation.

Grandt, A. F., Jr.↗
NASA NTRS1995

Gear Crack Propagation Investigation

Reduced weight is a major design goal in aircraft power transmissions. Some gear designs incorporate thin rims to help meet this goal. Thin rims, however, may lead to bending fatigue cracks. These cracks may propagate through a gear tooth or into the gear rim. A crack that propagates through a tooth would probably not be catastrophic, and ample warning of a failure could be possible. On the other hand, a crack that propagates through the rim would be catastrophic. Such cracks could lead to disengagement of a rotor or propeller from an engine, loss of an aircraft, and fatalities. To help create and validate tools for the gear designer, the NASA Lewis Research Center performed in-house analytical and experimental studies to investigate the effect of rim thickness on gear-tooth crack propagation. Our goal was to determine whether cracks grew through gear teeth (benign failure mode) or through gear rims (catastrophic failure mode) for various rim thicknesses. In addition, we investigated the effect of rim thickness on crack propagation life. A finite-element-based computer program simulated gear-tooth crack propagation. The analysis used principles of linear elastic fracture mechanics, and quarter-point, triangular elements were used at the crack tip to represent the stress singularity. The program had an automated crack propagation option in which cracks were grown numerically via an automated remeshing scheme. Crack-tip stress-intensity factors were estimated to determine crack-propagation direction. Also, various fatigue crack growth models were used to estimate crack-propagation life. Experiments were performed in Lewis' Spur Gear Fatigue Rig to validate predicted crack propagation results. Gears with various backup ratios were tested to validate crack-path predictions. Also, test gears were installed with special crack-propagation gages in the tooth fillet region to measure bending-fatigue crack growth. From both predictions and tests, gears with backup ratios (rim thickness divided by tooth height) of 3.3 and 1.0 produced tooth fractures, whereas a backup ratio of 0.3 produced rim fractures. For a backup ratio of 0.5, the experiments produced rim fractures and the predictions produced both rim and tooth fractures, depending on the initial geometry of the crack. Good correlation between predicted and measured crack growth was achieved when the fatigue crack-closure concept was introduced into the analysis. As the gear rim thickness decreased, the compressive cyclic stress in the gear-tooth fillet region increased. This retarded crack growth and increased the number of crack-propagation cycles to failure.

Source record↗
NASA NTRS1977

Preliminary evaluation of fiber composite reinforcement of truck frame rails

The use of graphite fiber/resin matrix composite to effectively reinforce a standard steel truck frame rail is studied. A preliminary design was made and it was determined that the reinforcement weight could be reduced by a factor of 10 when compared to a steel reinforcement. A section of a 1/3 scale reinforced rail was fabricated to demonstrate low cost manufacturing techniques. The scale rail section was then tested and increased stiffness was confirmed. No evidence of composite fatigue was found after 500,000 cycles to a fiber stress of 34,000 psi. The test specimen failed in bending in a static test at a load 50 percent greater than that predicted for a non-reinforced rail.

Faddoul, J. R.↗
NASA NTRS1992

Detection and characterization of fatigue cracks in thin metal plates by low frequency resonant model analysis

Low-frequency resonant model analysis, a technique for the detection and characterization of fatigue cracks in thin metal plates, which could be adapted to rapid scan or large area testing, is considered. Experimental data displaying a direct correlation between fatigue crack geometry and resonance frequency for the second vibrational plate mode are presented. FEM is used to calculate the mechanical behavior of the plates, and provides a comparison basis for the experimentally determined resonance frequency values. The waveform of the acoustic emission generated at the resonant frequency is examined; it provides the basis for a model of the interaction of fatigue crack faces during plate vibration.

Wincheski, B.↗
NASA NTRS1987

Random loading fatigue crack growth: Crack closure considerations

The prediction of fatigue crack growth is an important element of effective fracture control for metallic structures and mechanical components, especially in the aerospace industry. The prediction techniques available and applied today are mostly based on fatigue crack growth measurements determined in constant amplitude testing. However, while many service loadings are constant amplitude, many more loadings are random amplitude. An investigation to determine which statistics of random loadings are relevant to fatigue crack closure was conducted. The fundamentals of random processes and crack closure are briefly reviewed, then the relevance of certain random process parameters to the crack closure calculation are discussed qualitatively. A course for further research is outlined.

Ortiz, Keith↗
NASA NTRS1973

Effect of lubricant extreme pressure additives on rolling element fatigue life

The effects of surface active additives on rolling-element fatigue life were investigated with the five-ball fatigue tester at conditions where classical subsurface initiated rolling-element fatigue is the sole mode of failure. Test balls of AISI 52100, AISI M-50, and AISI 1018 were run with an acid-treated white oil containing either 2.5 percent sulfurized terpene, 1 percent didodecyl phosphite, or 5 percent chlorinated wax. In general, it was found that the influence of surface active additives was detrimental to rolling-element fatigue life. The chlorinated-wax additive significantly reduced fatigue life by a factor of 7. The base oil with the 2.5 percent sulfurized-terpene additive can reduce fatigue life by as much as 50 percent. No statistical change in fatigue life occurred with the base oil having the 1 percent didodecyl-phosphite additive. The additives used with the base oil did not change the ranking of the bearing steels where rolling-element fatigue life was of subsurface origin.

Parker, R. J.↗
NASA NTRS1994

On the measurement of the crack tip stress field as a means of determining Delta K(sub eff) under conditions of fatigue crack closure

The optical method of caustics has been successfully extended to enable stress intensity factors as low as 1MPa square root of m to be determined accurately for central fatigue cracks in 2024-T3 aluminium alloy test panels. The feasibility of using this technique to study crack closure, and to determine the effective stress intensity factor range, Delta K(sub eff), has been investigated. Comparisons have been made between the measured values of stress intensity factor, K(sub caus), and corresponding theoretical values, K(sub theo), for a range of fatigue cracks grown under different loading conditions. The values of K(sub caus) and K(sub theo) were in good agreement at maximum stress, where the cracks are fully open, while K(sub caus) exceeded K(sub theo) at minimum stress, due to crack closure. However, the levels of crack closure and values of Delta K(sub eff) obtained could not account for the variations of crack growth rate with loading conditions. It is concluded that the values of Delta K(sub eff), based on caustic measurements in a 1/square root of r stress field well outside the plastic zone, do not fully reflect local conditions which control crack tip behavior.

Wallhead, Ian R.↗
NASA NTRS2002

Evaluation of Fatigue Crack Growth and Fracture Properties of Cryogenic Model Materials

The criteria used to prevent failure of wind-tunnel models and support hardware were revised as part of a project to enhance the capabilities of cryogenic wind tunnel testing at NASA Langley Research Center. Specifically, damage-tolerance fatigue life prediction methods are now required for critical components, and material selection criteria are more general and based on laboratory test data. The suitability of two candidate model alloys (AerMet 100 and C-250 steel) was investigated by obtaining the fatigue crack growth and fracture data required for a damage-tolerance fatigue life analysis. Finally, an example is presented to illustrate the newly implemented damage tolerance analyses required of wind-tunnel model system components.

Newman, John A.↗
NASA NTRS2002

Influence of Crack-Tip Configurations on the Fracture Response of 0.04-Inch Thick 2024-T3 Aluminum Alloy Sheet

A series of fracture tests were conducted on Middle-crack tension M(T) and compact tension C(T) specimens to determine the effects of specimen type, specimen width, notch tip sharpness and buckling on the fracture behavior of cracked thin sheet (0.04 inch thick) 2024-T3 aluminum alloy material. A series of M(T) specimens were tested with three notch tip configurations: (1) a fatigue pre-cracked notch, (2) a 0.010-inch-diameter wire electrical discharge machined (EDM) notch, and (3) a EDM notch sharpened with a razor blade. The test procedures are discussed and the experimental results for failure stress, load vs. crack extension and the material stress-strain response are reported.

Johnston, William M.↗
DOE OSTI2023

FY23 status report on the development of new ASME Section III, Division 5 Class B rules

This report summarizes the work done in Fiscal Year 2023 on the development of the new American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 5, Class B rules to address the gaps identified for high temperature reactor designs. The summary of the design-by-analysis strain limit evaluation and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. This approach captures the elastic follow-up generated due to interactions of components with adjacent components, supports, and other connections in the power plant. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules, and the experimental data obtained from a family of Simplified Model Test based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2014

On the Correlation of Specific Film Thickness and Gear Pitting Life

The effect of the lubrication regime on gear performance has been recognized, qualitatively, for decades. Often the lubrication regime is characterized by the specific film thickness defined as the ratio of lubricant film thickness to the composite surface roughness. It can be difficult to combine results of studies to create a cohesive and comprehensive dataset. In this work gear surface fatigue lives for a wide range of specific film values were studied using tests done with common rigs, speeds, lubricant temperatures, and test procedures. This study includes previously reported data, results of an additional 50 tests, and detailed information from lab notes and tested gears. The dataset comprised 258 tests covering specific film values [0.47 to 5.2]. The experimentally determined surface fatigue lives, quantified as 10-percent life estimates, ranged from 8.7 to 86.8 million cycles. The trend is one of increasing life for increasing specific film. The trend is nonlinear. The observed trends were found to be in good agreement with data and recommended practice for gears and bearings. The results obtained will perhaps allow for the specific film parameter to be used with more confidence and precision to assess gear surface fatigue for purpose of design, rating, and technology development.

gears↗
NASA NTRS2015

On the Correlation of Specific Film Thickness and Gear Pitting Life

The effect of the lubrication regime on gear performance has been recognized, qualitatively, for decades. Often the lubrication regime is characterized by the specific film thickness defined as the ratio of lubricant film thickness to the composite surface roughness. It can be difficult to combine results of studies to create a cohesive and comprehensive dataset. In this work gear surface fatigue lives for a wide range of specific film values were studied using tests done with common rigs, speeds, lubricant temperatures, and test procedures. This study includes previously reported data, results of an additional 50 tests, and detailed information from lab notes and tested gears. The dataset comprised 258 tests covering specific film values (0.47 to 5.2). The experimentally determined surface fatigue lives, quantified as 10-percent life estimates, ranged from 8.7 to 86.8 million cycles. The trend is one of increasing life for increasing specific film. The trend is nonlinear. The observed trends were found to be in good agreement with data and recommended practice for gears and bearings. The results obtained will perhaps allow for the specific film parameter to be used with more confidence and precision to assess gear surface fatigue for purpose of design, rating, and technology development.

gears↗
NASA NTRS1957

Effect of Fatigue Crack on Static Strength: 2014-T6, 2024-T4, 6061-T6, 7075-T6 Open-Hole Monobloc Specimens

Static tensile test results are presented for specimens of 2014-T6, 2024-T4, 6061-T6, and 7075-T6 aluminum alloy containing fatigue cracks. The results are found to be in good agreement with the results reported for similar tests from other sources. The results indicate that the presence of a fatigue crack reduced the static strength, in all cases, by an amount larger than the corresponding reduction in net area; the 6061-T6 alloy specimens were least susceptible to the crack and the 7075-T6 alloy specimens were most susceptible. It is indicated that a 7075-T6 specimen may develop as little as one-third of the expected static tensile strength when the fatigue crack was consumed only one-fourth of the original area. It was found that the static strength was substantially higher for specimens which had stop holes drilled at the end of the fatigue crack.

Nordmark, Glenn E.↗
DOE OSTI2022

Uncertainty Quantification of Monolithic Tungsten Target Block Fatigue

The current STS spallation target design consists of 21 water cooled, tantalum clad, monolithic tungsten blocks. The target wheel assembly rotates such that each target block receives a direct proton pulse every 1.4 seconds (21 blocks / 15 Hz pulses). The quasi-steady heating induced by the repetitive beam pulses creates a significant mean stress distribution in the target. On top of this, the rapid energy deposition from a proton pulse induces dynamic stress waves that are of the same order of magnitude as the mean stresses. Over the design goal of 5,000 operational hours per year for a decade, each target must withstand over 130 million repetitions of these dynamic stress events. The fatigue life prediction of the target blocks is a complex sequence of simulations that depend upon a set of input parameters. For the tungsten block, the end goal is the fatigue factor-of-safety (FOS). This study documents a new structural analysis routine using software available to U.S. national laboratories (e.g. CUBIT, Sierra Multiphysics, Dakota) that enables more rapid target fatigue analysis. The increased throughput is amenable to parameter sensitivity and uncertainty quantification (UQ) studies. A set of input parameters (ultimate strength, fatigue strength, density, elastic modulus, Poisson’s ratio, thermal conductivity, coefficient of thermal expansion, specific heat, flow rate) with expected ranges are documented based on literature data, recent experimental testing, and engineering judgement. UQ bounds the resulting fatigue FOS at [0.5, 3.4] using epistemic interval analysis. These bounds are expected to be wider due to model effects (discretization) and beam effects (focus, offset) that were not included. Parameter sensitivity underscores the importance of ultimate strength and fatigue strength of irradiated tungsten on the fatigue calculations.

43 PARTICLE ACCELERATORS↗
NASA NTRS1980

Resonant-fatigue cracking apparatus

Apparatus produces controlled surface cracks in test specimens. It has been developed and is useful in production of surface cracks of controlled size and shape in fracture specimens. It consists of specially-designed stand-mounted clamping fixture, commercially available pneumatic actuator, and suitable sound-control mufflers.

Dorner, J. P.↗