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All sourcesNASA NTRSDOE OSTI
NASA NTRS1973

The effect of yield strength and ductility to fatigue damage

The cumulative damage of aluminium alloys with different yield strength and various ductility due to seismic loads was studied. The responses of an idealized beam with a centered mass at one end and fixed at the other end to El Centro's and Taft's earthquakes are computed by assuming that the alloys are perfectly elastoplastic materials and by using numerical technique. Consequently, the corresponding residual plastic strain can be obtained from the stress-strain relationship. The revised Palmgren-Miner cumulative damage theorem is utilized to calculate the fatigue damage. The numerical results show that in certain cases, the high ductility materials are more resistant to seismic loads than the high yield strength materials. The results also show that if a structure collapse during the earthquake, the collapse always occurs in the very early stage.

Yeh, H. Y.↗
NASA NTRS1972

Effect of cryogenic irradiation on NERVA structural alloys

Several alloys (Hastelloy X, AISI 347, A-286 bolts, Inconel 718, Al 7039-T63 and Ti-5Al-2.5Sn ELI) were irradiated in liquid nitrogen (140 R) to neutron fluences between 10 to the 17th power and 10 to the 19th power nvt (E greater than 1.0 Mev). After irradiation, tensile properties were obtained in liquid nitrogen without permitting any warmup except for some specimens which were annealed at 540 R. The usual trend of radiation damage typical for materials irradiated at and above room temperature was observed, such as an increase in strength and decrease in ductility. However, the damage at 140 R was greater because this temperature prevented the annealing of radiation-induced defects which occurs above 140 R.

Dixon, C. E.↗
NASA NTRS1980

Cyclic plasticity and failure of structural components

An analytical approach for low-cycle fatigue prediction is presented. The approach combines a cyclic plasticity model with the finite element method and a damage accumulation criterion for ductile metals. The cyclic plasticity model is based on the concept of the combination of several yield surfaces. The surfaces are related to the material uniaxial stress-strain curve idealized by piecewise linear segments. The damage criterion is based on the Coffin-Manson formulae modified for the mean stress variation effect. It is extended to the multiaxial varying stress-strain field and applied for both the crack initiation and the crack growth processes. The stable slow crack growth rate is approximated by the damage accumulation gradient computed from the cracked finite element models. This procedure requires fatigue testing data of only smooth specimens under constant strain amplitudes. The present approach is illustrated by numerical examples of an aircraft wing stiffened panel subjected to compression, which causes material yielding and residual tension.

Kalev, I.↗
NASA NTRS1983

Particulate erosion mechanisms

Particulate damage and erosion of ductile metals are today plaguing design and field engineers in diverse fields of engineering and technology. It was found that too many models and theories were proposed leading to much speculation from debris analysis and failure mechanism postulations. Most theories of solid particle erosion are based on material removal models which do not fully represent the actual physical processes of material removal. The various mechanisms proposed thus far are: melting, low-cycle fatigue, extrusion, delamination, shear localization, adhesive material transfer, etc. The experimental data on different materials highlighting the observed failure modes of the deformation and cutting wear processes using optical and scanning electron microscopy are presented. The most important mechanisms proved from the experimental observations of the specimens exposed to both spherical and angular particles are addressed, and the validity of the earlier theories discussed. Both the initial stages of damage and advanced stages of erosion were studied to gain a fundamental understanding of the process.

Veerabhadrarao, P.↗
NASA NTRS2020

Analysis of Open Hole Compression Specimens Using the CompDam Continuum Damage Mechanics Model

This report documents a validation study on the standard Open Hole Compression (OHC) laminate test specimen conducted as part of the NASA Advanced Composites Project (ACP). Tests were conducted on OHC specimens with hard, quasi-isotropic, and soft layups using digital image correlation and X-Ray computed tomography to capture the structural response and damage evolution. Progressive damage models were constructed for use with the CompDam continuum damage mechanics code following the best practices established during the ACP. Detailed interrogation of the analysis results and comparison with experimental measurements provide a basis for assessing the capability of the modeling approach for OHC. The structural response is found to be captured well, with strengths predicted within 3\% of the experimental values for hard and quasi-isotropic laminates. In the soft laminate, the model predicts failure to be more brittle than the nonlinear, ductile response that was measured. Damage states extracted from the models at the same load level as test measurements are overlaid to show directly the similarities and differences between test and analysis results. Studying the damage evolution predicted by the analysis reveals that the failure process is a competition between fiber damage and delamination/sub-laminate buckling, with fiber damage dominating the collapse in the hard laminate and sub-laminate buckling governing in the soft laminate. Finally, a series of parametric studies varying numerical solution parameters (mesh size, mass scaling) and physical properties (fiber direction compressive strength and toughness) reveal sensitivities and deficiencies of the model. To the authors' knowledge, this study is the first for OHC specimens to include detailed evaluation of damage mode interactions, direct overlay of predicted and measured damage states, and sensitivity of the predicted results to difficult-to-measure fiber direction material properties.

Continuum damage mechanics↗
NASA NTRS1972

Correlation of irradiation data using activation fluences and irradiation temperature.

A new method of correlating radiation damage data is tested using actual measured data taken from the open literature. This method, the activation fluence method, was found to be as accurate as other contemporary models with which it was compared. The new method also has several advantages over the other methods. The method employs a new entity, the activation fluence (time-integrated specific activation rate), as the independent variables in a regression model. Temperature at which the irradiation takes place is also a variable. Although the method was tested for a specific type of damage (change in nil-ductility transition temperature for A302-B steel) it has no inherent restrictions and is limited only by the imagination of the user.

Lynch, J. H.↗
NASA NTRS2003

Flaw Tolerance In Lap Shear Brazed Joints

This paper presents results of the second part of an on-going effort to gain better understanding of defect tolerance in braze joints. In the first part of this three-part series, we mechanically tested and modeled the strength of the lap joints as a function of the overlap distance. A failure criterion was established based on the zone damage theory, which predicts the dependence of the lap joint shear strength on the overlap distance, based on the critical size of a finite damage zone or an overloaded region in the joint. In this second part of the study, we experimentally verified the applicability of the damage zone criterion on prediction of the shear strength of the lap joint and introduced controlled flaws into the lap joints. The purpose of the study was to evaluate the lap joint strength as a function of flaw size and its location through mechanical testing and nonlinear finite element analysis (FEA) employing damage zone criterion for definition of failure. The results obtained from the second part of the investigation confirmed that the failure of the ductile lap shear brazed joints occurs when the damage zone reaches approximately 10% of the overlap width. The same failure criterion was applicable to the lap joints containing flaws.

Wang, Len↗
NASA NTRS2001

Improved Method Being Developed for Surface Enhancement of Metallic Materials

Surface enhancement methods induce a layer of beneficial residual compressive stress to improve the impact (FOD) resistance and fatigue life of metallic materials. A traditional method of surface enhancement often used is shot peening, in which small steel spheres are repeatedly impinged on metallic surfaces. Shot peening is inexpensive and widely used, but the plastic deformation of 20 to 40 percent imparted by the impacts can be harmful. This plastic deformation can damage the microstructure, severely limiting the ductility and durability of the material near the surface. It has also been shown to promote accelerated relaxation of the beneficial compressive residual stresses at elevated temperatures. Low-plasticity burnishing (LPB) is being developed as an improved method for the surface enhancement of metallic materials. LPB is being investigated as a rapid, inexpensive surface enhancement method under NASA Small Business Innovation Research contracts NAS3-98034 and NAS3-99116, with supporting characterization work at NASA. Previously, roller burnishing had been employed to refine surface finish. This concept was adopted and then optimized as a means of producing a layer of compressive stress of high magnitude and depth, with minimal plastic deformation (ref. 1). A simplified diagram of the developed process is given in the following figure. A single pass of a smooth, free-rolling spherical ball under a normal force deforms the surface of the material in tension, creating a compressive layer of residual stress. The ball is supported in a fluid with sufficient pressure to lift the ball off the surface of the retaining spherical socket. The ball is only in mechanical contact with the surface of the material being burnished and is free to roll on the surface. This apparatus is designed to be mounted in the conventional lathes and vertical mills currently used to machine parts. The process has been successfully applied to nickel-base superalloys by a team from the NASA Glenn Research Center, Lambda Research, and METCUT Research, as supported by the NASA Small Business Innovation Research Phase I and II programs, the Ultra Safe program, and the Ultra- Efficient Engine Technology (UEET) Program.

Gabb, Timothy P.↗
NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

This is the final report for the NASA funded project entitled "Crack Growth Prediction Methodology for Multi-Site Damage." The primary objective of the project was to create a capability to simulate curvilinear fatigue crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage. The second objective was to validate the capability by way of comparisons to experimental results. Both objectives have been achieved and the results are detailed herein. In the first part of the report, the crack tip opening angle (CTOA) fracture criterion, obtained and correlated from coupon tests to predict fracture behavior and residual strength of built-up aircraft fuselages, is discussed. Geometrically nonlinear, elastic-plastic, thin shell finite element analyses are used to simulate stable crack growth and to predict residual strength. Both measured and predicted results of laboratory flat panel tests and full-scale fuselage panel tests show substantial reduction of residual strength due to the occurrence of multi-site damage (MSD). Detailed comparisons of n stable crack growth history, and residual strength between the predicted and experimental results are used to assess the validity of the analysis methodology. In the second part of the report, issues related to crack trajectory prediction in thin shells; an evolving methodology uses the crack turning phenomenon to improve the structural integrity of aircraft structures are discussed, A directional criterion is developed based on the maximum tangential stress theory, but taking into account the effect of T-stress and fracture toughness orthotropy. Possible extensions of the current crack growth directional criterion to handle geometrically and materially nonlinear problems are discussed. The path independent contour integral method for T-stress evaluation is derived and its accuracy is assessed using a p- and hp-version adaptive finite element method. Curvilinear crack growth is simulated in coupon tests and in full-scale fuselage panel tests. Both T-stress and fracture toughness orthotropy are found to be essential to predict the observed crack paths. The analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically while insuring continuous airworthiness. Consequently, it will improve the technology to support the safe operation of the current aircraft fleet as well as the design of more damage-tolerant aircraft for the next generation fleet.

Chen, Chuin-Shan↗
NASA NTRS1980

Fracture and crack growth in orthotropic laminates

Solutions are developed for the two dimensional region containing unidirectional fibers with initial damage in the form of a notch, a rectangular cut out, and a circular hole. An ultimate stress failure criterion is used for both the fibers and the matrix, simple tension for the fibers, and shear failure for the matrix. Models which account for longitudinal matrix yielding and splitting as well as transverse matrix yielding and fiber breakage as a function of initial damage, material properties, and applied stress are presented. For ductile matrix composites the results indicate that longitudinal matrix yielding and transverse notch extension are the most significant forms of damage. The extent of the stable transverse damage is shown to be approximately constant, independent of initial notch length. In the case of brittle matrix composites (graphite/epoxy) longitudinal splitting is shown to be the dominant form of damage.

Goree, J. G.↗
NASA NTRS1977

Creep degradation in oxide-dispersion-strengthened alloys

Oxide dispersion strengthened Ni-base alloys in wrought bar form are studied for creep degradation effects similar to those found in thin gage sheet. The bar products evaluated included ODS-Ni, ODS-NiCr, and three types of advanced ODS-NiCrAl alloys. Tensile test specimens were exposed to creep at various stress levels at 1365 K and then tensile tested at room temperature. Low residual tensile properties, change in fracture mode, the appearance of dispersoid-free bands, grain boundary cavitation, and internal oxidation in the microstructure were interpreted as creep degradation effects. This work showed that many ODS alloys are subject to creep damage. Degradation of tensile properties occurred after very small amounts of creep strain, ductility being the most sensitive property. All the ODS alloys which were creep damaged possessed a large grain size. Creep damage appears to have been due to diffusional creep which produced dispersoid-free bands around boundaries acting as vacancy sources. Low angle and possibly twin boundaries acted as vacancy sources.

Whittenberger, J. D.↗
NASA NTRS1966

Controlled release device prevents damage from dynamic stresses

Controlled release device that retards motion by extruding or drawing a tapered ductile pin through a die will control launch vehicle motion at liftoff. The device prevents the damaging dynamic stresses that are imposed on the vehicle when it is instantaneously released at full thrust.

Burcham, T. W.↗
NASA NTRS2000

Ultrasonic Assessment of Impact-Induced Damage and Microcracking in Polymer Matrix Composites

The main objective of this NASA FAR project is to conduct ultrasonic assessment of impact-induced damage and microcracking in polymer matrix composites at various temperatures. It is believed that the proposed study of impact damage assessment on polymer matrix composites will benefit several NASA's missions and current interests, such as ballistic impact testing of composite fan containment and high strain rate deformation modeling of polymer matrix composites. Currently, impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

Liaw, Benjamin↗
NASA NTRS2000

Impact Delamination and Fracture in Aluminum/Acrylic Sandwich Plates

Impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F. Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

Liaw, Benjamin↗
NASA NTRS1985

Creep fatigue life prediction for engine hot section materials (isotropic)

The first two years of a two-phase program aimed at improving the high temperature crack initiation life prediction technology for gas turbine hot section components are discussed. In Phase 1 (baseline) effort, low cycle fatigue (LCF) models, using a data base generated for a cast nickel base gas turbine hot section alloy (B1900+Hf), were evaluated for their ability to predict the crack initiation life for relevant creep-fatigue loading conditions and to define data required for determination of model constants. The variables included strain range and rate, mean strain, strain hold times and temperature. None of the models predicted all of the life trends within reasonable data requirements. A Cycle Damage Accumulation (CDA) was therefore developed which follows an exhaustion of material ductility approach. Material ductility is estimated based on observed similarities of deformation structure between fatigue, tensile and creep tests. The cycle damage function is based on total strain range, maximum stress and stress amplitude and includes both time independent and time dependent components. The CDA model accurately predicts all of the trends in creep-fatigue life with loading conditions. In addition, all of the CDA model constants are determinable from rapid cycle, fully reversed fatigue tests and monotonic tensile and/or creep data.

Moreno, Vito↗
NASA NTRS1998

A Progressive Damage Methodology for Residual Strength Predictions of Notched Composite Panels

The translaminate fracture behavior of carbon/epoxy structural laminates with through-penetration notches was investigated to develop a residual strength prediction methodology for composite structures. An experimental characterization of several composite materials systems revealed a fracture resistance behavior that was very similar to the R-curve behavior exhibited by ductile metals. Fractographic examinations led to the postulate that the damage growth resistance was primarily due to fractured fibers in the principal load-carrying plies being bridged by intact fibers of the adjacent plies. The load transfer associated with this bridging mechanism suggests that a progressive damage analysis methodology will be appropriate for predicting the residual strength of laminates with through-penetration notches. A progressive damage methodology developed by the authors was used to predict the initiation and growth of matrix cracks and fiber fracture. Most of the residual strength predictions for different panel widths, notch lengths, and material systems were within about 10% of the experimental failure loads.

Coats, Timothy W.↗
NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

The objectives were to create a capability to simulate curvilinear crack growth and ductile tearing in aircraft fuselages subjected to widespread fatigue damage and to validate with tests. Analysis methodology and software program (FRANC3D/STAGS) developed herein allows engineers to maintain aging aircraft economically, while insuring continuous airworthiness, and to design more damage-tolerant aircraft for the next generation. Simulations of crack growth in fuselages were described. The crack tip opening angle (CTOA) fracture criterion, obtained from laboratory tests, was used to predict fracture behavior of fuselage panel tests. Geometrically nonlinear, elastic-plastic, thin shell finite element crack growth analyses were conducted. Comparisons of stress distributions, multiple stable crack growth history, and residual strength between measured and predicted results were made to assess the validity of the methodology. Incorporation of residual plastic deformations and tear strap failure was essential for accurate residual strength predictions. Issue related to predicting crack trajectory in fuselages were also discussed. A directional criterion, including T-stress and fracture toughness orthotropy, was developed. Curvilinear crack growth was simulated in coupon and fuselage panel tests. Both T-stress and fracture toughness orthotropy were essential to predict the observed crack paths. Flapping of fuselages were predicted. Measured and predicted results agreed reasonable well.

Chen, Chuin-Shan↗
NASA NTRS1989

Characterization of failure processes in tungsten copper composites under fatigue loading conditions

A fractographic and metallographic investigation was performed on specimens of a tungsten fiber reinforced copper matrix composite (9 vol percent), which had experienced fatigue failures at elevated temperatures. Major failure modes and possible failure mechanisms, with an emphasis placed on characterizing fatigue damage accumulation, were determined. Metallography of specimens fatigued under isothermal cyclic loading suggested that fatigue damage initiates in the matrix. Cracks nucleated within the copper matrix at grain boundaries, and they propagated through cavity coalescence. The growing cracks subsequently interacted with the reinforcing tungsten fibers, producing a localized ductile fiber failure. Examinations of interrupted tests before final failure confirmed the suggested fatigue damage processes.

Kim, Yong-Suk↗