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At least 19 records

All sources NASA NTRS DOE OSTI

NASA NTRS1982

Life prediction and constitutive behavior: Overview

The evolution of programs to investigate high temperature consititutive behavior and develop cyclic life prediction methods is reviewed. Contracts granted for developing and verifying workable engineering methods for the calculation, in advance of service, of the local stress-strain response at the critical life governing location in typical hot section components as well as the resultant cyclic crack initiation and crack growth lifetimes are listed. The Langley fatigue facility is being upgraded to include: (1) a servocontrolled testing machine for high temperature crack growth; (2) three servocontrolled tension/torsion machines for biaxial studies; (3) a HOST/satellite computer for data acquisition, processing, storage, and retrieval; and (4) HCV/LCF machines for cumulative damage studies.

Halford, G. R.↗

NASA NTRS1983

Life prediction and constitutive behavior

One of the primary drivers that prompted the initiation of the hot section technology (HOST) program was the recognized need for improved cyclic durability of costly hot section components. All too frequently, fatigue in one form or another was directly responsible for the less than desired durability, and prospects for the future weren't going to improve unless a significant effort was mounted to increase our knowledge and understanding of the elements governing cyclic crack initiation and propagation lifetime. Certainly one of the important factors is the ability to perform accurate structural stress-strain analyses on a routine basis to determine the magnitudes of the localized stresses and strains since it is these localized conditions that govern the initiation and crack growth processes. Developing the ability to more accurately predict crack initiation lifetimes and cyclic crack growth rates for the complex loading conditions found in turbine engine hot sections is of course the ultimate goal of the life prediction research efforts. It has been found convenient to divide the research efforts into those dealing with nominally isotropic and anisotropic alloys; the latter for application to directionally solidified and single crystal turbine blades.

Halford, G. R.↗

NASA NTRS1985

Lewis' enhanced laboratory for research into the fatigue and constitutive behavior of high temperature materials

Lewis Research Center's high temperature fatigue laboratory has undergone significant changes resulting in the addition of several new experimental capabilities. New materials testing systems have been installed enabling research to be conducted in multiaxial fatigue and deformation at high temperature, as well as cumulative creep-fatigue damage wherein the relative failure-life levels are widely separated. A key component of the new high-temperature fatigue and structures laboratory is a local, distributed computer system whose hardware and software architecture emphasizes a high degree of configurability, which in turn, enables the researcher to tailor a solution to the problem at hand.

Mcgaw, Michael A.↗

NASA NTRS1986

Constitutive modeling for isotropic materials (HOST)

The results of the third year of work on a program which is part of the NASA Hot Section Technology program (HOST) are presented. The goals of this program are: (1) the development of unified constitutive models for rate dependent isotropic materials; and (2) the demonstration of the use of unified models in structural analyses of hot section components of gas turbine engines. The unified models selected for development and evaluation are those of Bodner-Partom and of Walker. A test procedure was developed for assisting the generation of a data base for the Bodner-Partom model using a relatively small number of specimens. This test procedure involved performing a tensile test at a temperature of interest that involves a succession of strain-rate changes. The results for B1900+Hf indicate that material constants related to hardening and thermal recovery can be obtained on the basis of such a procedure. Strain aging, thermal recovery, and unexpected material variations, however, preluded an accurate determination of the strain-rate sensitivity parameter is this exercise. The effects of casting grain size on the constitutive behavior of B1900+Hf were studied and no particular grain size effect was observed. A systematic procedure was also developed for determining the material constants in the Bodner-Partom model. Both the new test procedure and the method for determining material constants were applied to the alternate material, Mar-M247 . Test data including tensile, creep, cyclic and nonproportional biaxial (tension/torsion) loading were collected. Good correlations were obtained between the Bodner-Partom model and experiments. A literature survey was conducted to assess the effects of thermal history on the constitutive behavior of metals. Thermal history effects are expected to be present at temperature regimes where strain aging and change of microstructure are important. Possible modifications to the Bodner-Partom model to account for these effects are outlined. The use of a unified constitutive model for hot section component analyses was demonstrated by applying the Walker model and the MARC finite-element code to a B1900+Hf airfoil problem.

Chan, Kwai S.↗

NASA NTRS2007

Strain Measurement Using FBG on COPV in Stress Rupture Test

White Sands Test Facility (WSTF) was requested to perform ambient temperature hydrostatic pressurization testing of a Space Transportation System (STS) 40-in. Kevlar Composite Overwrapped Pressure Vessel (COPV). The 40-in. vessel was of the same design and approximate age as the STS Main Propulsion System (MPS) and Orbiter Maneuvering System (OMS) vessels. The NASA Engineering Safety Center (NESC) assembled a team of experts and conducted an assessment that involved a review of national Kevlar COPY data. During the review, the STS COPVs were found to be beyond their original certification of ten years. The team observed that the likelihood of STS COPV Stress rupture, a catastrophic burst before leak failure mode, was greater than previously believed. Consequently, a detailed assessment of remaining stress rupture life became necessary. Prior to STS-114, a certification deviation was written for two flights of OV-103 (Discovery) and OV-104 (Atlantis) per rationale that was based on an extensive review of the Lawrence Livermore National Laboratories, COPV data, and revisions to the STS COPV stress levels. In order to obtain flight rationale to extend the certification deviation through the end of the Program, the Orbiter Project Office has directed an interagency COPV team to conduct further testing and analysis to investigate conservatism in the stress rupture model and evaluate material age degradation. Additional analysis of stress rupture life requires understanding the fiber stresses including stress that occurs due to thru-wall composite compression in COPV components. Data must be obtained at both zero gauge pressure (pre-stress) and at the component operating pressure so that this phenomenon can be properly evaluated. The zero gauge pressure stresses are predominantly a result of the autofrettage process used during vessel manufacture. Determining these pre-stresses and the constitutive behavior of the overwrap at pressure will provide necessary information to better predict the remaining life of the STS COPVs. The primary test objective is obtaining data to verify the hypothesis of a radially oriented thru-thickness stress-riser in the COPV composite whose magnitude is a function of the applied pressure and the load history. The anticipated load dependent response follows from the constitutive behavior of the composite overwrap so data to quantify its nonlinear and time dependent response will be sought. The objective of the Fiber Braggs Gratings (FBGs) were to advance the state-of-the-art by developing techniques using FBG sensors that are capable of assessing stress-rupture degradation in Kevlar COPVs in a health monitoring mode (1). Moreover, they sought to answer questions of how embedded sensors affect overall integrity of the structure. And lastly, they sought to provide an important link in the overall stress rupture study that will help close the loop on the COPV fabrication process. NDE inspection methods will be used from start to finish and FBG will be an integral link within the overall chain.

Banks, Curtis↗

NASA NTRS1996

Mechanics of Granular Materials (MGM)

The constitutive behavior of uncemented granular materials such as strength, stiffness, and localization of deformations are to a large extend derived from interparticle friction transmitted between solid particles and particle groups. Interparticle forces are highly dependent on gravitational body forces. At very low effective confining pressures, the true nature of the Mohr envelope, which defines the Mohr-Coulomb failure criterion for soils, as well as the relative contribution of each of non-frictional components to soil's shear strength cannot be evaluated in terrestrial laboratories. Because of the impossibility of eliminating gravitational body forces on earth, the weight of soil grains develops interparticle compressive stresses which mask true soil constitutive behavior even in the smallest samples of models. Therefore the microgravity environment induced by near-earth orbits of spacecraft provides unique experimental opportunities for testing theories related to the mechanical behavior of terrestrial granular materials. Such materials may include cohesionless soils, industrial powders, crushed coal, etc. This paper will describe the microgravity experiment, 'Mechanics of Granular Materials (MGM)', scheduled to be flown on Space Shuttle-MIR missions. The paper will describe the experiment's hardware, instrumentation, specimen preparation procedures, testing procedures in flight, as well as a brief summary of the post-mission analysis. It is expected that the experimental results will significantly improve the understanding of the behavior of granular materials under very low effective stress levels.

Alshibli, Khalid A.↗

NASA NTRS1990

Experimental observations and finite element analysis of the initiation of fiber microbuckling in notched composite laminates

A better understanding of the factors that affect the semi-circular edge-notched compressive strength is developed, and the associated failure mode(s) of thermoplastic composite laminates with multidirectional stacking sequences are identified. The primary variables in this investigation are the resin nonlinear shear constitutive behavior, stacking sequence (orientation of plies adjacent to the 0 degree plies), resin-rich regions between the 0 degree plies and the off-axis supporting plies, fiber/matrix interfacial bond strength, and initial fiber waviness. Two thermoplastic composite material systems are used in this investigation. The materials are the commercial APC-2 (AS4/PEEK) and a poor interface experimental material, AU4U/PEEK, designed for this investigation. Notched compression specimens are studied at 21, 77, and 132 C. Geometric and material nonlinear two-dimensional finite element analysis is used to model the initiation of fiber microbuckling of both the ideal straight fiber and the more realistic initially wavy fiber. The effects of free surface, fiber constitutive properties, matrix constitutive behavior, initial fiber curvature, and fiber/matrix interfacial bond strength on fiber microbuckling initiation strain levels are considered.

Guynn, E. Gail↗

DOE OSTI2024

A high-resolution pseudo-polygon discrete element model for regional sea ice

Here, this work presents a pseudo-polygon discrete element model for high-resolution sea ice simulations. A scale-invariant bonded particle contact model is proposed to model joints between sea ice floes based on the smeared fracture model and a lattice spring beam model, and the Mohr–Coulomb failure criterion is implemented to represent the shearing failure mechanism of sea ice packings under complex loadings. All mechanical parameters of the bond model can be directly determined from laboratory tests. Validations of the proposed model are made by investigations of mechanical response and failure criteria of field sea ice sheets. Compared with the field observations of sea ice from satellite radar and in situ stress sensors, the proposed model is capable of reproducing the typical constitutive behavior and the Coulomb friction envelope of field sea ice. Finally, the proposed discrete element sea ice model is used to study the effect of loading rates on mechanical behavior including failure strength of regional sea ice.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1989

Nonlinear mesomechanics of composites with periodic microstructure

This work is concerned with modeling the mechanical deformation or constitutive behavior of composites comprised of a periodic microstructure under small displacement conditions at elevated temperature. A mesomechanics approach is adopted which relates the microimechanical behavior of the heterogeneous composite with its in-service macroscopic behavior. Two different methods, one based on a Fourier series approach and the other on a Green's function approach, are used in modeling the micromechanical behavior of the composite material. Although the constitutive formulations are based on a micromechanical approach, it should be stressed that the resulting equations are volume averaged to produce overall effective constitutive relations which relate the bulk, volume averaged, stress increment to the bulk, volume averaged, strain increment. As such, they are macromodels which can be used directly in nonlinear finite element programs such as MARC, ANSYS and ABAQUS or in boundary element programs such as BEST3D. In developing the volume averaged or efective macromodels from the micromechanical models, both approaches will require the evaluation of volume integrals containing the spatially varying strain distributions throughout the composite material. By assuming that the strain distributions are spatially constant within each constituent phase-or within a given subvolume within each constituent phase-of the composite material, the volume integrals can be obtained in closed form. This simplified micromodel can then be volume averaged to obtain an effective macromodel suitable for use in the MARC, ANSYS and ABAQUS nonlinear finite element programs via user constitutive subroutines such as HYPELA and CMUSER. This effective macromodel can be used in a nonlinear finite element structural analysis to obtain the strain-temperature history at those points in the structure where thermomechanical cracking and damage are expected to occur, the so called damage critical points of the structure.

Walker, Kevin P.↗

DOE OSTI2025

Micro-structural features and material properties impact on adhesive metal joints via computational modeling and machine learning

The quality of structural bonding in practical applications depends on various factors arising from materials, pre-processing conditions, and manufacturing. Understanding how these factors influence bonding performance and determining their relative importance are of significant interest. Thus, this study evaluates the effects of microstructural features and material properties on the structural strength of adhesively-bonded metal joints at the submillimeter scale, utilizing a combination of Finite Element Modeling (FEM) and Machine Learning (ML) with Gradient Boosting Regression (GBR). The microstructural features include adhesive thickness, internal voids within the adhesive, adherend-adhesive interfacial voids, void size and volume fraction, and surface roughness. The material properties include the constitutive behavior of the adhesive, as well as the adherend-adhesive interfacial strength and fracture energy. The changes in structural strength and morphologies of the bonded metal structures with respect to different microstructural features and material properties were clarified by FEM. By further leveraging ML-GBR, the sequence of importance of these factors affecting bonding performance across various scenarios was summarized. This work provides valuable insights into the development of improved structural bonding for adhesive joints in industries such as automotive , aerospace, and beyond.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Computer simulation of the mathematical modeling involved in constitutive equation development: Via symbolic computations

Development of new material models for describing the high temperature constitutive behavior of real materials represents an important area of research in engineering disciplines. Derivation of mathematical expressions (constitutive equations) which describe this high temperature material behavior can be quite time consuming, involved and error prone; thus intelligent application of symbolic systems to facilitate this tedious process can be of significant benefit. A computerized procedure (SDICE) capable of efficiently deriving potential based constitutive models, in analytical form is presented. This package, running under MACSYMA, has the following features: partial differentiation, tensor computations, automatic grouping and labeling of common factors, expression substitution and simplification, back substitution of invariant and tensorial relations and a relational data base. Also limited aspects of invariant theory were incorporated into SDICE due to the utilization of potentials as a starting point and the desire for these potentials to be frame invariant (objective). Finally not only calculation of flow and/or evolutionary laws were accomplished but also the determination of history independent nonphysical coefficients in terms of physically measurable parameters, e.g., Young's modulus, was achieved. The uniqueness of SDICE resides in its ability to manipulate expressions in a general yet predefined order and simplify expressions so as to limit expression growth. Results are displayed when applicable utilizing index notation.

Arnold, S. M.↗

NASA NTRS1989

Procedures for characterizing an alloy and predicting cyclic life with the total strain version of Strainrange Partitioning

Procedures are presented for characterizing an alloy and predicting cyclic life for isothermal and thermomechanical fatigue conditions by using the total strain version of strainrange partitioning (TS-SRP). Numerical examples are given. Two independent alloy characteristics are deemed important: failure behavior, as reflected by the inelastic strainrange versus cyclic life relations; and flow behavior, as indicated by the cyclic stress-strain-time response (i.e., the constitutive behavior). Failure behavior is characterized by conducting creep-fatigue tests in the strain regime, wherein the testing times are reasonably short and the inelastic strains are large enough to be determined accurately. At large strainranges, stress-hold, strain-limited tests are preferred because a high rate of creep damage per cycle is inherent in this type of test. At small strainranges, strain-hold cycles are more appropriate. Flow behavior is characterized by conducting tests wherein the specimen is usually cycled far short of failure and the wave shape is appropriate for the duty cycle of interest. In characterizing an alloy pure fatigue, or PP, failure tests are conducted first. Then depending on the needs of the analyst a series of creep-fatigue tests are conducted. As many of the three generic SRP cycles are featured as are required to characterize the influence of creep on fatigue life (i.e., CP, PC, and CC cycles, respectively, for tensile creep only, compressive creep only, and both tensile and compressive creep). Any mean stress effects on life also must be determined and accounted for when determining the SRP inelastic strainrange versus life relations for cycles featuring creep. This is particularly true for small strainranges. The life relations thus are established for a theoretical zero mean stress condition.

Saltsman, James F.↗

NASA NTRS2020

An Improved Plastically Dilatant Unified Viscoplastic Constitutive Formulation for Multiscale Analysis of Polymer Matrix Composites Under High Strain Rate Loading

Polymer matrix composites are commonly used to fabricate energy-absorbing structures expected to experience impact loading. As such, a detailed understanding of the dynamic response of the constituent materials is necessary. Since the rate, temperature, and pressure dependence of carbon fiber reinforced polymer matrix composites are primarily manifestations of the rate, temperature, and pressure dependence of the polymer matrix, it is crucial that the constitutive behavior of the matrix be accurately characterized. In this work, an existing unified viscoplastic constitutive formulation is extended to ensure thermodynamic consistency and to more accurately account for the tension-compression asymmetry observed in the response of polymeric materials. A new plastic potential function is proposed, and elementary loading conditions are utilized to determine relations between model constants to ensure nonnegative plastic dissipation, a necessary thermodynamic requirement. Expressions for plastic Poisson’s ratios are derived and are bounded by enforcing nonnegative plastic dissipation. The model is calibrated against available experimental data from tests conducted over a range of strain rates, temperatures, and loading cases on a representative thermoset epoxy; good correlation between simulations and experimental data is obtained. Temperature rises due to the conversion of plastic work to heat are computed via the adiabatic heat energy equation. The viscoplastic polymer model is then used as a constitutive model in the generalized method of cells micromechanics theory to investigate the effects of matrix adiabatic heating on the high strain rate response of a unidirectional composite. The thermodynamic consistency of the model ensures plastic dissipation can only cause an increase in temperature. Simulation results indicate that significant thermal softening due to the conversion of plastic work to heat is observed in the composite for matrix dominated deformation modes.

Impact loading↗

NASA NTRS2000

Assessment of Constitutive and Stability Behavior of Sands Under Plane Strain Condition

A series of biaxial (plane strain) experiments were conducted on three sands under low (15 kPa) and high (100 kPa) confining pressure conditions to investigate the effects of specimen density, confining pressure, and sand grains size and shape on the constitutive and stability behavior of granular materials. The three sands used in the experiments were fine, medium, and coarse-grained uniform silica sands with rounded, sub-angular, and angular grains, respectively. Specimen deformation was readily monitored and analyzed with the help of a grid pattern imprinted on the latex membrane. The overall stress-strain behavior is strongly dependent on the specimen density, confining pressure, sand grain texture, and the resulting failure mode(s). That became evident in different degrees of softening responses at various axial strains. The relationship between the constitutive behavior and the specimens' modes of instability is presented. The failure in all specimens was characterized by two distinct and opposite shear bands. It was found that the measured dilatancy angles increase as the sand grains' angularity and size increase. The measured shear band inclination angles are also presented and compared with classical Coulomb and Roscoe solutions.

Alshibli, Khalid A.↗

NASA NTRS1985

Constitutive modeling for isotropic materials

Constitutive theories were evaluated against a large uniaxial and multiaxial data base that was generated as part of this work. The experimental approach was to determine the constitutive behavior of Rene 80 under a multitude of conditions that are important in the design of gas turbine blades and vanes. The experimental and analytical goals of this program were successfully accomplished. A new multiaxial constitutive model which can represent the complex nonlinear high temperature behavior of Rene 80 was developed. The model was extensively verified on data at several temperatures.

Ramaswamy, V. G.↗

NASA NTRS2007

Micromechanics of Spray-On Foam Insulation

Understanding the thermo-mechanical response of the Space Shuttle External Tank spray-on foam insulation (SOFI) material is critical, to NASA's Return to Flight effort. This closed-cell rigid polymeric foam is used to insulate the metallic Space Shuttle External Tank, which is at cryogenic temperatures immediately prior to and during lift off. The shedding of the SOFI during ascent led to the loss of the Columbia, and eliminating/minimizing foam lass from the tank has become a priority for NASA as it seeks to resume scheduled space shuttle missions. Determining the nature of the SOFI material behavior in response to both thermal and mechanical loading plays an important role as any structural modeling of the shedding phenomenon k predicated on knowledge of the constitutive behavior of the foam. In this paper, the SOFI material has been analyzed using the High-Fidelity Generalized Method of Cells (HFGMC) micromechanics model, which has recently been extended to admit a triply-periodic 3-D repeating unit cell (RUC). Additional theoretical extensions that mere made in order to enable modeling of the closed-cell-foam material include the ability to represent internal boundaries within the RUC (to simulated internal pores) and the ability to impose an internal pressure within the simulated pores. This latter extension is crucial as two sources contribute to significant internal pressure changes within the SOFI pores. First, gas trapped in the pores during the spray process will expand or contract due to temperature changes. Second, the pore pressure will increase due to outgassing of water and other species present in the foam skeleton polymer material. With HFGMC's new pore pressure modeling capabilities, a nonlinear pressure change within the simulated pore can be imposed that accounts for both of these sources, in addition to stmdar&-thermal and mechanical loading; The triply-periodic HFGMC micromechanics model described above was implemented within NASA GRC's MAC/GMC software package, giving the model access to a range of nonlinear constitutive models for the polymeric foam skeleton material. A repeating unit cell architecture was constructed that, while relatively simple, still accounts for the geometric anisotropy of the porous foam microstructure and its thin walls and thicker edges. With the lack of reliable polymeric foam skeleton materia1 properties, many simulations were executed aimed at backing out these material properties. Then, using these properties, predictions of the thermo-mechanical behavior of the foam, including calculated internal applied pressure profiles, were performed and compared with appropriate experimental data.

Bednarcyk, Brett A.↗

NASA NTRS2000

Bithermal Low-Cycle Fatigue Evaluation of Automotive Exhaust System Alloy SS409

This investigation provides, for the first time, cyclic strainrange-controlled, thermomechanical fatigue results for the ferritic stainless steel alloy SS409. The alloy has seen extensive application for automotive exhaust system components. The data were generated to calibrate the Total Strain Version of the Strainrange Partitioning (TS-SRP) method for eventual application to the design and durability assessment of automotive exhaust systems. The thermomechanical cyclic lifetime and cyclic stress-strain constitutive behavior for alloy SS409 were measured using bithermal tests cycling between isothermal extremes of 400 and 800 C. Lives ranged up to 10,000 cycles to failure with hold-times of 0.33 to 2.0 minutes. The bithermal fatigue behavior is compared to isothermal, strain-controlled fatigue behavior at both 400 and 800 C. Thermomechanical cycling was found to have a profound detrimental influence on the fatigue failure resistance of SS409 compared to isothermal cycling. Supplementary bithermal cyclic stress-strain constitutive tests with hold-times ranging from 40 seconds up to 1.5 hours were conducted to calibrate the TS-SRP equation for extrapolation to longer lifetime predictions. Observed thermomechanical (bithermal) fatigue lives correlated well with lives calculated using the calibrated TS-SRP equations: 70% of the bithermal fatigue data fall within a factor of 1.2 of calculated life; 85% within a factor of 1.4; and 100% within a factor of 1.8.

Lu, Gui-Ying↗

NASA NTRS1999

Synergistic Effects of Physical Aging and Damage on Long-Term Behavior of Polymer Matrix Composites

The research consisted of two major parts, first modeling and simulation of the combined effects of aging and damage on polymer composites and secondly an experimental phase examining composite response at elevated temperatures, again activating both aging and damage. For the simulation, a damage model for polymeric composite laminates operating at elevated temperatures was developed. Viscoelastic behavior of the material is accounted for via the correspondence principle and a variational approach is adopted to compute the temporal stresses within the laminate. Also, the effect of physical aging on ply level stress and on overall laminate behavior is included. An important feature of the model is that damage evolution predictions for viscoelastic laminates can be made. This allows us to track the mechanical response of the laminate up to large load levels though within the confines of linear viscoelastic constitutive behavior. An experimental investigation of microcracking and physical aging effects in polymer matrix composites was also pursued. The goal of the study was to assess the impact of aging on damage accumulation, in ten-ns of microcracking, and the impact of damage on aging and viscoelastic behavior. The testing was performed both at room and elevated temperatures on [+/- 45/903](sub s) and [02/903](sub s) laminates, both containing a set of 90 deg plies centrally located to facilitate investigation of microcracking. Edge replication and X-ray-radiography were utilized to quantify damage. Sequenced creep tests were performed to characterize viscoelastic and aging parameters. Results indicate that while the aging times studied have limited ]Influence on damage evolution, elevated temperature and viscoelastic effects have a profound effect on the damage mode seen. Some results are counterintuitive, including the lower strain to failure for elevated temperature tests and the catastrophic failure mode observed for the [+/- 45/9O3](sub s), specimens. The fracture toughness for transverse cracks increases with increasing temperature for both systems: transverse cracking was completely absent prior to failure in [+/- 45/903](sub s), and was suppressed for [02/903](sub s). No significant effect of damage on aging or viscoelastic parameters was observed.

Brinson, L. Cate↗