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At least 1,783 records · Page 99

DESIGN AND TESTING OF A 275 BAR 700 DEGREE CELSIUS EXPANDER FOR AN INTEGRALLY GEARED SUPERCRITICAL CO2 COMPANDER

An integrally-geared (IG) compressor-expander (compander) for use in a nominal 10 MW-scale concentrated solar power (CSP) supercritical carbon dioxide (sCO2) plant application was designed, manufactured, and tested. The integrally-geared compander (IGC) developed for this application comprises multiple pinion shafts interacting through a single bull gear to create a compact package and utilize a lowcost, low-speed driver. The present work will detail the design of the high-pressure high-temperature expander casing on an integrally geared frame, and illustrate how the project successfully mitigated the risk of fatigue and creep while allowing for rapid thermal transients in the design. Furthermore, test data from the test campaign will be presented supporting the analysis. Test results also show temperature profiles during operation exceeding 720° Celsius.

wilkes, jason↗

Review of sonic fatigue technology

From the early-1960s until the mid-1980s, there was very little theoretical development for sonic fatigue prediction. Design nomographs based on simple theoretical models and results of specially designed tests were developed for most common aircraft structures. The use of advanced composites in the 1980s, however, generated an increased interest in development of more sophisticated theoretical models because of the possibilities for a much wider range of structural designs. The purpose of this report is to review sonic fatigue technology and, in particular, to assess recent developments. It also suggests a plan for a coordinated program of theoretical and experimental work to meet the anticipated needs of future aerospace vehicles.

Clarkson, B. L.↗

Inhibition of Micro-pitting by Tribofilm-Forming ZrO 2 Nanocrystal Lubricant Additives: A Micro-pitting Rig and Transmission Electron Microscope Study

The drive to reduce fuel consumption in transportation has encouraged the emergence of low viscosity lubricants to reduce viscous losses in the engine, drivetrain, and other components. However, viscosity reduction increases the risk of surface damage, thus motivating the development of new anti-wear (AW) additives. Capped ZrO 2 nanocrystals (NCs) in base oils have been shown to form AW tribofilms within microscale sliding contacts. However, the potential of ZrO 2 NCs to protect surfaces subjected to rolling-sliding contact from macroscale damage, such as micro-pitting, remains unexplored. Here, we explore the ability of ZrO 2 NCs to form protective tribofilms under harsh conditions using a micro-pitting rig (MPR), consisting of a three ring-on-roller configuration. The experiments were conducted in polyalphaolephin (PAO) base oil, with and without 5 nm diameter ZrO 2 NCs, at two levels of slide-to-roll ratio (SRR) (30% and 0%) and at variable test durations up to long durations (119 h). MPR results showed the use of ZrO 2 NCs gives rise to the formation of a tribofilm covering the roller surfaces and decreases the initiation and propagation of micro-pits compared to tests in pure PAO base stock. Transmission electron microscopy (TEM) performed on focused ion beam (FIB) milled cross-sectional samples of the roller surfaces revealed the growth of dense and 50–100 nm thick ZrO 2 -based tribofilms independent of (SRR), indicating the potential for robust micro-pitting fatigue protection. Nevertheless, small cracks localized within the near surface region of the roller tested at the most severe conditions (30% SRR and 119 h) were observed. The initiation of these cracks was directly related to the presence of manganese sulphide (MnS) inclusions in the steel, revealed using TEM combined with energy dispersive spectroscopy (EDS). Furthermore, the results highlight the benefits of the protective tribofilms formed by ZrO 2 NCs and suggest approaches for further optimizing their use.

36 MATERIALS SCIENCE↗

Tensile and fatigue data for irradiated and unirradiated AISI 310 stainless steel and titanium - 5 percent aluminum - 2.5 percent tin: Application of the method of universal slopes

Irradiated and unirradiated tensile and fatigue specimens of AISI 310 stainless steel and Ti-5Al-2.5Sn were tested in the range of 100 to 10,000 cycles to failure to determine the applicability of the method of universal slopes to irradiated materials. Tensile data for both materials showed a decrease in ductility and increase in ultimate tensile strength due to irradiation. Irradiation caused a maximum change in fatigue life of only 15 to 20 percent for both materials. The method of universal slopes predicted all the fatigue data for the 310 SS (irradiated as well as unirradiated) within a life factor of 2. For the titanium alloy, 95 percent of the data was predicted within a life factor of 3.

Debogdan, C. E.↗

Smooth Pursuit Saccade Amplitude Modulation During Exposure to Microgravity

Russian investigators have reported changes in pursuit tracking of a vertically moving point stimulus during space flight. Early in microgravity, changes were manifested by decreased eye movement amplitude (undershooting) and the appearance of correction saccades. As the flight progressed, pursuit of the moving point stimulus deteriorated while associated saccadic movements were unchanged. Immediately postflight there was an improved execution of active head movements indicating that the deficiencies in pursuit function noted in microgravity may be of central origin. In contrast, tests of two cosmonauts showed that horizontal and vertical smooth pursuit were unchanged inflight. However, results of corresponding saccadic tasks showed a tendency toward the overshooting of a horizontal target early inflight with high accuracy developing later inflight, accompanied by an increased saccade velocity and a trend toward decreased saccade latency. Based on these equivocal results, we have further investigated the effects of space flight on the smooth pursuit mechanism during and after short duration flight, and postflight on returning MIR crewmembers. Sinusoidal target movement was presented horizontally at frequencies of 0.33 and 1.0 Hz. Subjects were asked to perform two trials for each stimulus combination: (1) moving eyes-only (EO) and (2) moving eyes and head (EH) with the target motion. Peak amplitude was 30 deg for 0.33 Hz trials and 15 deg for the 1.0 Hz trials. The relationship between saccade amplitude and peak velocity were plotted as a main sequence for each phase of flight, and linear regression analysis allowed us to determine the slope of each main sequence plot. The linear slopes were then combined for each flight phase for each individual subject. The main sequence for both EO and EH trials at both the 0.33 and 1.0 Hz frequencies during flight for the short duration flyers showed a reduction in saccade velocity and amplitude when compared to the preflight main sequence . This difference in the regression slopes between flight phase, head/eye condition (EO or EH), and pursuit target frequency was observed across all subjects (statistically significant at the p<0.02, df= 2). It is interesting to note that postflight for the short duration flyers there was an immediate recovery to the preflight main sequence across all trials. There were no significant differences observed between the preflight slopes for either head movement condition (EO vs. EH). When the immediate postflight (R+O) regression slopes were compared with the preflight slopes, there was a tendency (not significant) for both saccade amplitude and peak velocity to increase during the postflight testing. This tendency had vanished by R+ 1. Of particular interest was the redistribution of saccades during the latter stages of the flight and immediately postflight in the EO condition. At the 1.0 Hz frequency the saccades tended to be clustered near the lowest target velocity. It was also interesting to note that gaze performance (eye in skull + head in space) was consistently better during the EH condition; a finding also observed by our Russian colleagues. As the results of the long duration flight become available we expect that they will not only show that postflight effects will be similar to those observed during the short duration flights, but will also last for a greater period of time following flight. It is not clear what mechanism is responsible for the decreased peak saccadic velocity during flight unless the change is related to the control of retinal slip. For example, it is possible that saccades will tend to initially undershoot their targets by a small percentage and these saccades are then followed, if vision is available, by a small augmenting corrective saccade. It has been postulated that the functional significance of this undershooting tendency is to maintain the spatial representation of the target on the same side of the fovea (as opposedo racing across the fovea) and hence in the same cerebral hemisphere that initiated the primary saccade thus minimizing delays caused by an intra-hemispheric transfer of information . One could also speculate that with saccade velocities greater than normal, additional corrective saccades would be required to bring the target back on the fovea. A less plausible explanation of our findings could be fatigue. Yet it seems unlikely that our subjects would show lower velocities on all inflight test days while showing increased saccade velocities immediately following space flight where fatigue is usually the greatest. Finally, the redistribution effect noted late inflight is likely caused by adaptive changes. Overall, corrective saccades appeared to be used in maintaining gaze on target; reducing retinal slip and assisting space travelers in maintaining clear vision throughout the different phases of the space flight.

Reschke, M. F.↗

Teleoperator comfort and psychometric stability: Criteria for limiting master-controller forces of operation and feedback during telemanipulation

The following question is addressed: How much force should operators exert, or experience, when operating a telemanipulator master-controller for sustained periods without encountering significant fatigue and discomfort, and without loss of stability in psychometric perception of force. The need to minimize exertion demands to avoid fatigue is diametrically opposed by the need to present a wide range of force stimuli to enhance perception of applied or reflected forces. For 104 minutes subjects repetitiously performed a series of 15 s isometric pinch grasps; controlled at 5, 15, and 25 percent of their maximum voluntary strength. Cyclic pinch grasps were separated by rest intervals of 7.5 and 15 s. Upon completion of every 10 minute period, subjects interrupted grasping activities to gage the intensity of fatigue and discomfort in the hand and forearm using a cross-modal matching technique. A series of psychometric tests were then conducted to determine accuracy and stability in the subject's perception of force experienced. Results showed that onset of sensations of discomfort and fatigue were dependent upon the magnitude of grasp force, work/rest ratio, and progression of task. Declines in force magnitude estimation slopes, indicating a reduction in force perception sensitivity, occurred with increased grasp force when work/rest ratios were greater than 1.0. Specific recommendations for avoiding discomfort and shifts in force perception, by limiting pinch grasp force required for master-controller operation and range of force reflection or work/rest ratios, are provided.

Wiker, Steven F.↗

Development of a high temperature fatigue sensor.

An experimental program was conducted to extend the Tracor Safety Gauge (patent pending) to elevated temperature service. The Safety Gauge is based on a conductive composite device which can be fabricated to function as a fatigue sensor that undergoes an irreversible resistance increase which results from cumulative strain damage. Prototype sensors were developed which appear capable of 1000 deg F operation for short periods of time (approaching one hour); however, bonding difficulties currently limit their use to about 775 deg F. The resistance change of the sensor was generally on the order of 400% or greater as the fatigue life of a titanium alloy (Ti-5Al-2.5Sn) test specimen was approached.

Wells, T. L.↗

Performance of solar shields

The loss of the micrometeoroid shield from the Orbital Workshop section of Skylab I, about 63 seconds after lift-off, proved to be the harbinger of a prodigious effort to quickly develop a workable substitute for the carefully tailored passive portion of the thermal-control system. The paper describes the intensive ten-day around-the-clock effort in which numerous potential thermal-shield materials were assessed, and during which period ten specific shield designs were developed and carried through various stages of development and test. Thermal-shield materials data are discussed, including optical, strength, fatigue, outgassing, tackiness, ultraviolet radiation, and material 'memory' properties.

Schwinghamer, R. J.↗

National Transonic Facility Fan Blade prepreg material characterization tests

The test program for the basic prepreg materials used in process development work and planned fabrication of the national transonic facility fan blade is presented. The basic prepreg materials and the design laminate are characterized at 89 K, room temperature, and 366 K. Characterization tests, test equipment, and test data are discussed. Material tests results in the warp direction are given for tensile, compressive, fatigue (tension-tension), interlaminar shear and thermal expansion.

Klich, P. J.↗

A combined Eulerian-Lagrangian two-phase analysis of the SSME HPOTP nozzle plug trajectories

As a result of high cycle fatigue, hydrogen embrittlement, and extended engine use, it was observed in testing that the trailing edge on the first stage nozzle plug in the High Pressure Oxygen Turbopump (HPOTP) could detach. The objective was to predict the trajectories followed by particles exiting the turbine. Experiments had shown that the heat exchanger soils, which lie downstream of the turbine, would be ruptured by particles traveling in the order of 360 ft/sec. An axisymmetric solution of the flow was obtained from the work of Lin et. al., who used INS3D to obtain the solution. The particle trajectories were obtained using the method of de Jong et. al., which employs Lagrangian tracking of the particle through the Eulerian flow field. The collision parameters were obtained from experiments conducted by Rocketdyne using problem specific alloys, speeds, and projectile geometries. A complete 3-D analysis using the most likely collision parameters shows maximum particle velocities of 200 ft/sec. in the heat exchanger region. Subsequent to this analysis, an engine level test was conducted in which seven particles passed through the turbine but no damage was observed on the heat exchanger coils.

Garcia, Robert↗

The fatigue behavior of composite laminates under various mean stresses

A method is developed for predicting the S-N curve of a composite laminate which is subjected to an arbitrary stress ratio, R (minimum stress/maximum stress). The method is based on the measuring of the S-N behavior of two distinct cases, tension-tension and compression-compression fatigue loadings. Using these parameters, expressions are formulated that estimate the fatigue behavior under any stress ratio loading. Experimental results from the testing of graphite/epoxy laminates, with various structures, are compared with the predictions and show good agreement.

Rotem, A.↗

Detecting Leaks With An Infrared Camera

Proposed test reveals small leak in gas pipe - for example, leak through fatigue crack induced by vibration - even though insulation covers pipe. Infrared-sensitive video camera aimed at part(s) containing suspected leak(s). Insulated pipe pressurized with gas that absorbs infrared light. If crack were present, escaping gas travels along outside of pipe until it reached edge of insulation. Gas emerging from edge of insulation appears as dark cloud in video image.

Easter, Barry P.↗

Review of modelling small-crack behavior and fatigue-life predictions for aluminum alloys

The small-crack effect, where small fatigue cracks grow faster and at lower stress-intensity factors than large cracks, has been found to be significant for many materials and loading conditions. In this paper, plasticity effects and crack-closure modelling of small fatigue cracks are reviewed. A crack-closure model with a cyclic-plastic-zone-corrected effective stress-intensity factor range (related to the cyclic J-integral) and microstructural data on crack-initiation sites were used to calculate small-crack growth rates and fatigue lives for unnotched and notched specimens made of two aluminum alloys. The crack-closure transient from the plastic wake was shown to be the dominant cause of the small-crack effect and plasticity effects on the cyclic-plastic-zone-corrected stress-intensity factor range were negligible except at extremely high stress levels. Small-crack growth rates and fatigue lives under both constant-amplitude and spectrum loading from tests and analyses agreed well.

CRACK CLOSURE MODELLING↗

A Review Of Modelling Small-Crack Behavior And Fatigue-Life Predictions For Aluminum Alloys

The small-crack effect, where small fatigue cracks grow faster and at lower stress-intensity factors than large cracks, has been found to be significant for many materials and loading conditions. In this paper, plasticity effects and crack-closure modelling of small fatigue cracks are reviewed. A crack-closure model with a cyclic-plastic zone-corrected effective stress-intensity factor range (related to the cyclic J-integral) and microstructural data on crack-initiation sites were used to calculate small-crack growth rates and fatigue lives for unnotched and notched specimens made of two aluminum alloys. The crack-closure transient from the plastic wake was shown to be the dominant cause of the small-crack effect and plasticity effects on the cyclic-plastic zone-corrected stress-intensity factor range were negligible except at extremely high stress levels. Small-crack growth rates and fatigue lives under both constant-amplitude and spectrum loading from tests and analyses agreed well.

Newman, J. C., Jr.↗

Cyclic Fatigue of Brittle Materials with an Indentation-Induced Flaw System

The ratio of static to cyclic fatigue life, or 'h ratio', was obtained numerically for an indentation flaw system subjected to sinusoidal loading conditions. Emphasis was placed on developing a simple, quick lifetime prediction tool. The solution for the h ratio was compared with experimental static and cyclic fatigue data obtained from as-indented 96 wt.% alumina specimens tested in room-temperature distilled water.

Choi, Sung R.↗

Fatigue Analyses Under Constant- and Variable-Amplitude Loading Using Small-Crack Theory

Studies on the growth of small cracks have led to the observation that fatigue life of many engineering materials is primarily "crack growth" from micro-structural features, such as inclusion particles, voids, slip-bands or from manufacturing defects. This paper reviews the capabilities of a plasticity-induced crack-closure model to predict fatigue lives of metallic materials using "small-crack theory" under various loading conditions. Constraint factors, to account for three-dimensional effects, were selected to correlate large-crack growth rate data as a function of the effective stress-intensity factor range (delta-Keff) under constant-amplitude loading. Modifications to the delta-Keff-rate relations in the near-threshold regime were needed to fit measured small-crack growth rate behavior. The model was then used to calculate small-and large-crack growth rates, and to predict total fatigue lives, for notched and un-notched specimens under constant-amplitude and spectrum loading. Fatigue lives were predicted using crack-growth relations and micro-structural features like those that initiated cracks in the fatigue specimens for most of the materials analyzed. Results from the tests and analyses agreed well.

Newman, J. C., Jr.↗

Application of Single Crystal Failure Criteria: Theory and Turbine Blade Case Study

The orientation of the single crystal material within a structural component is known to affect the strength and life of the part. The first stage blade of the High Pressure Fuel Turbopump (HPFTP)/ Alternative Turbopump Development (ATD), of the Space Shuttle Main Engine (SSME) was used to study the effects of secondary axis'orientation angles on the failure rate of the blade. A new failure criterion was developed based on normal and shear strains on the primary crystallographic planes. The criterion was verified using low cycle fatigue (LCF) specimen data and a finite element model of the test specimens. The criterion was then used to study ATD/HPFTP first stage blade failure events. A detailed ANSYS finite element model of the blade was used to calculate the failure parameter for the different crystallographic orientations. A total of 297 cases were run to cover a wide range of acceptable orientations within the blade. Those orientations are related to the base crystallographic coordinate system that was created in the ANSYS finite element model. Contour plots of the criterion as a function of orientation for the blade tip and attachment were obtained. Results of the analysis revealed a 40% increase in the failure parameter due to changing of the primary and secondary axes of material orientations. A comparison between failure criterion predictions and actual engine test data was then conducted. The engine test data comes from two ATD/HPFTP builds (units F3- 4B and F6-5D), which were ground tested on the SSME at the Stennis Space Center in Mississippi. Both units experienced cracking of the airfoil tips in multiple blades, but only a few cracks grew all the way across the wall of the hollow core airfoil.

Sayyah, Tarek↗