Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “FRETTING”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 163 records · Page 9

Advanced Rotorcraft Transmission (ART) program summary

The Advanced Rotorcraft Transmission (ART) Program was initiated to advance the state of the art for rotorcraft transmissions. The goal of the ART Program was to develop and demonstrate the technologies needed to reduce transmission weight by 25 pct. and reduce noise by 10 dB while obtaining a 5000 hr 'mean time between failure'. The research done under the ART Program is summarized. A split path design was selected as best able to meet the program goals. Key part technologies needed for this design were identified, studied, and developed. Two of these technologies are discussed in detail: the load sharing of split path designs including the use of a compliant elastomeric torque splitter and the application of a high ratio, low pitch line velocity gear mesh. Development of an angular contact spherical roller bearing, transmission error analysis, and fretting fatigue testing are discussed. The technologies for a light weight, quiet, and reliable rotorcraft transmission were demonstrated.

Krantz, T. L.↗

CO2 and clathrate as past erosive agents on Mars

The debate on the history of the Martian atmosphere continues without resolution. Much hinges on a satisfactory solution to the problem of what liquid was responsible for the extensive development of canyons, channels, fretted terrain, and similar features. The 1960s and 1970s saw much debate about the roles of various fluids, namely water or brine, liquid CO2, or H2O sources in CO2 clathrate (CC), or magma. The last was discounted long ago, CC is largely ignored, and the most recent look at CO2 was by ourselves, utilizing the phase diagrams for the CO2-H2O system. In this article, we will further investigate this dilemma.

Lambert, R. ST.J.↗

Advanced Rotorcraft Transmission (ART) Program summary

The Advanced Rotorcraft Transmission (ART) Program was initiated to advance the state of the art for rotorcraft transmissions. The goal of the ART Program was to develop and demonstrate the technologies needed to reduce transmission weight by 25 pct and reduce noise by 10 dB while obtaining a 5000 hr 'mean time between failure'. The research done under the ART Program is summarized. A split path design was selected as best able to meet the program goals. Key part technologies needed for this design were identified, studied, and developed. Two of these technologies are discussed in detail: the load sharing of split path designs including the use of a compliant elastomeric torque splitter and the application of a high ratio, low pitch line velocity gear mesh. Development of an angular contact spherical roller bearing, transmission error analysis, and fretting fatigue testing are discussed. The technologies for a light weight, quiet, and reliable rotorcraft transmission were demonstrated.

Krantz, T. L.↗

Effects of Cyclic Loading on Mechanical Behavior of 24S-T4 and 75S-T6 Aluminum Alloys and SAE 4130 Steel

An investigation was conducted to determine the effects of cyclic loading on the mechanical behavior of 24S-T4 and 75S-T6 aluminum alloys and SAE 4130 steel. Specimens of the three materials were subjected to various numbers of prior fatigue cycles both below and above the fatigue limits. Special slow-bend tests were employed to show the effects of prior cycles of fatigue stressing on the transition temperature to brittle fracture for SAE 4130 steel and on the energy-absorption capacity of the aluminum alloys. Micrographic studies were made to observe and measure crack formation and propagation and additional special tests were conducted to supplement the results of the slow-bend tests. These included Charpy impact tests, mirohardness surveys, tension tests, and fretting-corrosion studies.

STEELS↗

Quality optimization of thermally sprayed coatings produced by the JP-5000 (HVOF) gun using mathematical modeling

Currently, thermal barrier coatings (TBC) of gas-turbine blades and similar applications have centered around the use of zirconia as a protective coating for high thermal applications. The advantages of zirconia include low thermal conductivity and good thermal shock resistance. Thermally sprayed tungsten carbide hardface coatings are used for a wide range of applications spanning both the aerospace and other industrial markets. Major aircraft engine manufacturers and repair facilities use hardface coatings for original engine manufacture (OEM), as well as in the overhaul of critical engine components. The principle function of these coatings is to resist severe wear environments for such wear mechanisms as abrasion, adhesion, fretting, and erosion. The (JP-5000) thermal spray gun is the most advanced in the High Velocity Oxygen Fuel (HVOF) systems. Recently, it has received considerable attention because of its relative low cost and its production of quality coatings that challenge the very successful but yet very expensive Vacuum Plasma Spraying (VPS) system. The quality of thermal spray coatings is enhanced as porosity, oxidation, residual stress, and surface roughness are reduced or minimized. Higher densification, interfacial bonding strength, hardness and wear resistance of coating are desirable features for quality improvement.

Tawfik, Hazem↗

The Characteristics of Fatigue Damage in the Fuselage Riveted Lap Splice Joint

An extensive data base has been developed to form the physical basis for new analytical methodology to predict the onset of widespread fatigue damage in the fuselage lap splice joint. The results of detailed destructive examinations have been cataloged to describe the physical nature of MSD in the lap splice joint. ne catalog includes a detailed description, e.g., crack initiation, growth rates, size, location, and fracture morphology, of fatigue damage in the fuselage lap splice joint structure. Detailed examinations were conducted on a lap splice joint panel removed from a full scale fuselage test article after completing a 60,000 cycle pressure test. The panel contained a four bay region that exhibited visible outer skin cracks and regions of crack link-up along the upper rivet row. Destructive examinations revealed undetected fatigue damage in the outer skin, inner skin, and tear strap regions. Outer skin fatigue cracks were found to initiate by fretting damage along the faying surface. The cracks grew along the faying surface to a length equivalent to two to three skin thicknesses before penetrating the outboard surface of the outer skin. Analysis of fracture surface marker bands produced during full scale testing revealed that all upper rivet row fatigue cracks contained in a dim bay region grow at similar rates; this important result suggests that fracture mechanics based methods can be used to predict the growth of outer skin fatigue cracks in lap splice structure. Results are presented showing the affects of MSD and out-of-plane pressure loads on outer skin crack link-up.

Piascik, Robert S.↗

Exploring for Martian Life

Terrestrial life appears to have arisen very quickly during late accretion, sometime between approximately 3.5 and 4.2 Ga. During this same time, liquid water appears to have been abundant at the surface of Mars and it is quite plausable that life originated there as well. We now believe that the last common ancestor of terrestrial life was a sulfur-metabolizing microbe that lived at high temperatures. Rooting of the RNA tree in thermophily probably reflects high temperature "bottle-necking" of the biosphere by giant impacts during late accretion, sometime after life had originated. If high temperature bottle-necking is a general property of early biosphere development, Martian life may have also developed in close association with hydrothermal systems. Several independent lines of evidence suggest that hydrothermal processes have played an important role during the geological history of Mars. Because hydrothermal deposits on Earth are known to capture and retain abundant microbial fossil information, they are considered prime targets in the search for an ancient Martian biosphere. An important step in planning for future landed missions to Mars is the selection of priority targets for high resolution orbital mapping. Geotectonic terranes on Mars that provide a present focus for ongoing site selection studies include channels located along the margins of impact crater melt sheets, or on the slopes of ancient Martian volcanoes, chaotic and fretted terranes where shallow subsurface heat sources are thought to have interacted with ground ice, and the floors of calderas and rifted basins. Orbital missions in 1996, 1998 and 2001 will provide opportunities for high resolution geological mapping at key sites in such terranes, as a basis for selecting targets for future landed missions for exopaleontology.

Farmer, Jack D.↗

Subsurface Stress Fields in Single Crystal (Anisotropic) Contacts

Single crystal superalloy turbine blades used in high pressure turbomachinery are subject to conditions of high temperature, triaxial steady and fatigue 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. Techniques for evaluating two and three dimensional subsurface stress fields in anisotropic contacts are presented in this report. Figure 1 shows typical damper contact locations in a turbine blade. The subsurface stress results are used for evaluating contact fatigue life at damper contacts and dovetail attachment regions in single crystal nickel-base superalloy turbine blades.

Arakere, Nagaraj K.↗

Obliquity, Ice Sheets, and Layered Sediments on Mars: What Spacecraft Observations and Climate Models are Telling Us

The Mars Odyssey Gamma-Ray Spectrometer (GRS) data present a quandary: On the one hand, large deposits of (inferred) water ice are located where thermal models suggest they would form and best be protected, e.g., if deposited during periods of higher obliquity. On the other hand, the volume mixing ratios (approx. 70%) are so high that diffusive deposition of water in regolith pore space (which is the process assumed by these models) cannot be the primary formation mechanism. Furthermore, given that the water is inferred to be so close to the surface (less than a few 10's of cm's), it must be in communication with the atmosphere on time scales that are geologically relatively short (10(exp 3)-10(exp 6) years); therefore the water cannot be archaic. Considering the GRS data, images of mantled, fretted, and disaggregated terrain, and new climate modeling of Mars orbital cycles, we are led to an alternate conclusion about the ice deposits: that they form as subaerial ice sheets. This scenario not only provides a simple explanation for these observations, but may also help explain the formation of globally distributed, sedimentary layered deposits.

Richardson, M. I.↗

Subsurface Stress Fields In Single Crystal (Anisotropic) Contacts

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.

Arakere, Nagaraj K.↗

Subsurface Stress Fields in FCC Single Crystal Anisotropic Contacts

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 high cycle fatigue (HCF) failure modes observed in these blades during operation include crystallographic crack initiation/propagation on octahedral planes, and non-crystallographic 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, based on the adaptation of a stress function method outlined by Lekhnitskii. Numerical results are presented for cylindrical and spherical anisotropic contacts, using finite element analysis (FEA). Effects of crystal orientation on stress response and fatigue life are examined. Obtaining accurate subsurface stress results for anisotropic single crystal contact problems require extremely refined three-dimensional (3-D) finite element grids, especially in the edge of contact region. Obtaining resolved shear stresses (RSS) on the principal slip planes also involves considerable post-processing work. For these reasons it is very advantageous to develop analytical solution schemes for subsurface stresses, whenever possible.

Arakere, Nagaraj K.↗

Prediction of Crack Growth under Variable-Amplitude Loading in Thin-Sheet 2024-T3 Aluminum Alloys

The present paper is concerned with the application of a "plasticity-induced" crack closure model to study fatigue crack growth under various load histories. The model was based on the Dugdale model but modified to leave plastically deformed material in the wake of the advancing crack. The model was used to correlate crack growth rates under constant-amplitude loading and then used to predict crack growth under variable-amplitude and spectrum loading on thin-sheet 2024- T3 aluminum alloys. Predicted crack-opening stresses agreed well with test data from the literature. The crack-growth lives agreed within a factor of two for single and repeated spike overloads/underloads and within 20 percent for spectrum loading. Differences were attributed to fretting-product-debris-induced closure and three-dimensional affects not included in the model.

Newman, J. C., Jr.↗

Hydrothermal systems on Mars: an assessment of present evidence

Hydrothermal processes have been suggested to explain a number of observations for Mars, including D/H ratios of water extracted from Martian meteorites, as a means for removing CO2 from the Martian atmosphere and sequestering it in the crust as carbonates, and as a possible origin for iron oxide-rich spectral units on the floors of some rifted basins (chasmata). There are numerous examples of Martian channels formed by discharges of subsurface water near potential magmatic heat sources, and hydrothermal processes have also been proposed as a mechanism for aquifer recharge needed to sustain long term erosion of sapping channels. The following geological settings have been identified as targets for ancient hydrothermal systems on Mars: channels located along the margins of impact crater melt sheets and on the slopes of ancient volcanoes; chaotic and fretted terranes where shallow subsurface heat sources are thought to have interacted with ground ice; and the floors of calderas and rifted basins (e.g. chasmata). On Earth, such geological environments are often a locus for hydrothermal mineralization. But we presently lack the mineralogical information needed for a definitive evaluation of hypotheses. A preferred tool for identifying minerals by remote sensing methods on Earth is high spatial resolution, hyperspectral, near-infrared spectroscopy, a technique that has been extensively developed by mineral explorationists. Future efforts to explore Mars for ancient hydrothermal systems would benefit from the application of methods developed by the mining industry to look for similar deposits on Earth. But Earth-based exploration models must be adapted to account for the large differences in the climatic and geological history of Mars. For example, it is likely that the early surface environment of Mars was cool, perhaps consistently below freezing, with the shallow portions of hydrothermal systems being dominated by magma-cryosphere interactions. Given the smaller gravitational field, declining atmospheric pressure, and widespread, permeable megaregolith on Mars, volatile outgassing and magmatic cooling would have been more effective than on Earth. Thus, hydrothermal systems are likely to have had much lower average surface temperatures than comparable geological settings on Earth. The likely predominance of basaltic crust on Mars suggests that hydrothermal fluids and associated deposits should be enriched in Fe, Mg, Si and Ca, with surficial deposits being dominated by lower temperature, mixed iron oxide and carbonate mineralogies.

Review↗

Crustal Evolution of the Protonilus Mensae Area, Mars

Despite research by numerous geologists and geo- physicists, the age and origin of the martian crustal dichotomy remain uncertain. Models for the origin of this dichotomy involve single or multiple impact, mantle megaplumes, primordial crustal asymmetry, and plate tectonics. Most of these models imply a Noachian age for the dichotomy. A major problem common to all genetic models is the difficulty separating the features resulting from the primary cause for the dichotomy from features due to younger fault- ing, impact cratering, volcanism, deposition, and erosion. highlands (the dichotomy boundary) approximates a small circle that ranges in latitude from about -10 deg. in Elysium Planitia to about +45 deg. north of Arabia Terra. For much of its length the boundary is characterized by relatively steep scarps separating highland plateau to the south from lowland plains to the north, generally with a complex transition zone on the lowland side of these scarps. These scarps are almost certainly due to normal faulting. The type fretted terrain, which defines the boundary in north-central Arabia Terra, also is characterized by scarps but has under- gone a more complex history of faulting and dissection [13]. In some places, notably in the Acidalia Planitia region, the dichotomy boundary is gradational. In the Tharsis region the boundary is obscured by younger volcanics.

McGill, G. E.↗

Ancient Giant Basin/Aquifer System in the Arabia Region, Mars, and Its Influence on the Evolution of the Highland-Lowland Boundary

Ancient geologic and hydrologic phenomena on Mars observed through the magnetic data provide windows to the ancient past through the younger Argyre and Hellas impacts, the northern plains basement and the rock materials that mantle the basement, and the Tharsis and Elysium magmatic complexes (recently referred to as superplumes). These signatures, coupled with highly degraded macrostructures (tectonic features that energetic planet during its embryonic development (0.5 Ga or so of activity) with an active dynamo and magnetosphere. One such window into the ancient past occurs northwest of the Hellas impact basin in Arabia Tern. Arabia Terra is one of the few water-rich equatorial regions of Mars, as indicated I through impact crater and elemental information. This region records many unique characteristics, including predominately Noachian materials, a highland-lowland boundary region that is distinct from other boundary regions, the presence of very few macrostructures when compared to the rest of the cratered highlands, the largest region of fretted terrain on Mars, outflow channels such as Mamers Valles that do not have obvious origins, and distinct albedo, thermal inertia, gravity, magnetic, and elemental signatures.

Dohm, J. M.↗

A Noachian/Hesperian Hiatus and Erosive Reactivation of Martian Valley Networks

Despite new evidence for persistent flow and sedimentation on early Mars, it remains unclear whether valley networks were active over long geologic timescales (10(exp 5)-10(exp 8) yr), or if flows were persistent only during multiple discrete episodes of moderate (approx. 10(exp 4) yr) to short (<10 yr) duration. Understanding the long-term stability/variability of valley network hydrology would provide an important control on paleoclimate and groundwater models. Here we describe geologic evidence for a hiatus in highland valley network activity while the fretted terrain formed, followed by a discrete reactivation of persistent (but possibly variable) erosive flows. Additional information is included in the original extended abstract.

Irwin, R. P., III.↗

Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications

Surface enhancement technologies such as shot peening, laser shock peening (LSP), and low plasticity burnishing (LPB) can provide substantial fatigue life improvement. However, to be effective, the compressive residual stresses that increase fatigue strength must be retained in service. For successful integration into turbine design, the process must be affordable and compatible with the manufacturing environment. LPB provides thermally stable compression of comparable magnitude and even greater depth than other methods, and can be performed in conventional machine shop environments on CNC machine tools. LPB provides a means to extend the fatigue lives of both new and legacy aircraft engines and ground-based turbines. Improving fatigue performance by introducing deep stable layers of compressive residual stress avoids the generally cost prohibitive alternative of modifying either material or design. The X-ray diffraction based background studies of thermal and mechanical stability of surface enhancement techniques are briefly reviewed, demonstrating the importance of minimizing cold work. The LPB process, tooling, and control systems are described. An overview of current research programs conducted for engine OEMs and the military to apply LPB to a variety of engine and aging aircraft components are presented. Fatigue performance and residual stress data developed to date for several case studies are presented including: * The effect of LPB on the fatigue performance of the nickel based super alloy IN718, showing fatigue benefit of thermal stability at engine temperatures. * An order of magnitude improvement in damage tolerance of LPB processed Ti-6-4 fan blade leading edges. * Elimination of the fretting fatigue debit for Ti-6-4 with prior LPB. * Corrosion fatigue mitigation with LPB in Carpenter 450 steel. *Damage tolerance improvement in 17-4PH steel. Where appropriate, the performance of LPB is compared to conventional shot peening after exposure to engine operating temperatures.

Prevey, Paul S.↗

New Oxide Ceramic Developed for Superior High-Temperature Wear Resistance

Ceramics, for the most part, do not have inherently good tribological properties. For example friction coefficients in excess of 0.7 have been reported for silicon nitride sliding on silicon nitride or on bearing steel (ref. 1). High friction is always accompanied by considerable wear. Despite their inherently poor tribological properties, the high strength and high toughness of silicon nitride (Si3N4) ceramics has led to their successful use in tribological applications (refs. 1 to 4). The upper temperature limit for the application of Si3N4 as wear-resistant material is limited by reaction with the tribological environment (ref. 3). Silicon nitride is known to produce a thin silicon dioxide film with easy shear capability that results in low friction and low wear in a moist environment (ref. 5). At elevated temperatures, the removal of the reaction product that acts as lubricant causes the friction coefficient to increase and, consequently, the wear performance to become poor. New materials are sought that will have wear resistance superior to that of Si3N4 at elevated temperatures and in harsh environments. A new class of oxide ceramic materials has been developed with potential for excellent high-temperature wear resistance. The new material consists of a multicomponent oxide with a two-phase microstructure, in which the wear resistance of the mixed oxide is significantly higher than that of the individual constituents. This is attributed to the strong constraining effects provided by the interlocking microstructures at different length scales, to the large aspect ratio of the phases, to the strong interphase bonding, and to the residual stresses. Fretting wear tests were conducted by rubbing the new ceramic material against boron carbide (B4C). The new ceramic material produced a wear track groove on B4C, suggesting significantly higher wear resistance for the oxide ceramic. The new material did not suffer from any microstructural degradation after the wear test. The wear rate of the new ceramic material at 600 C was determined to be on the order of 10-10 mm3/N-m, which is 3 to 5 orders of magnitude lower than that for the current state-of-theart wear-resistant materials (Si3N4and B4C). The friction coefficient of the new ceramic materials is on the order of 0.4, which is significantly lower than that of silicon nitride. This new class of oxide materials has shown considerable potential for applications requiring high wear resistance at high temperatures and in harsh environments. New understanding of the wear behavior of ceramic materials is emerging as a result of the surprisingly high wear resistance of two-phase oxide ceramics. There is excellent potential for further improvements in the wear resistance of oxide ceramics through optimizing the microstructure and altering the crystallographic properties of specific oxide materials as a second phase to reduce the coefficient of friction at elevated temperatures.

Sayir, Ali↗