Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “crack damage”

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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Mitigation of Crack Damage in Metallic Materials

A system designed to mitigate or heal crack damage in metallic materials has been developed where the protected material or component is coated with a low-melting temperature film. After a crack is formed, the material is heated, melting the film which then infiltrates the crack opening through capillary action. Upon solidification, the healing material inhibits further crack damage in two ways. While the crack healing material is intact, it acts like an adhesive that bonds or bridges the crack faces together. After fatigue loading damages, the healing material in the crack mouth inhibits further crack growth by creating artificially-high crack closure levels. Mechanical test data show that this method sucessfully arrests or retards crack growth in laboratory specimens.

Leser, Patrick E.↗
NASA NTRS1972

Nondestructive determination of fatigue crack damage in composites using vibration tests.

The vibration response of glass reinforced epoxy and polyester laminates was investigated. The complex modulus and the damping capacity were measured as fatigue crack damage accumulated. Changes in the Young's modulus as well as the damping capacity correlated with the amount of crack damage. The damping was especially sensitive to debonding of the reinforcement from the resin matrix. Measurement of these vibration response changes shows promise as a means to nondestructively test the structural integrity of filament-reinforced composite structural members.

Dibenedetto, A. T.↗
NASA NTRS1989

Energy analysis of crack-damage interaction

The energy release rates associated with a main crack propagating into a surrounding damage zone, and a damage zone translation relative to the main crack, as well as an energy of interaction between the two are analyzed. The displacement and stress fields for the crack-damage interaction problem are reconstructed employing a semi-empirical stress analysis and experimental evaluation of the average craze density in the crazed zone.

Chudnovsky, A.↗
NASA NTRS2018

Simulation of Stochastic Mud-Crack Damage Formation in an Environmental Barrier Coating

The integrated Finite Element Analysis–Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to simulate the formation of mudflat-cracks from thermomechanical loading on a multi-layered Environmental Barrier Coating (EBC) system deposited on a ceramic substrate. FEAMAC/CARES combines MAC/GMC multiscale composite micromechanics code with CARES/Life probabilistic multiaxial failure criteria code and Abaqusfinite element analysis. In this work, step function elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio finite elements enabled the depiction of crack boundaries and formation of mudflat patterned damage. Demonstrated examples include finite element models of button–sized disk–shaped 3-D specimen, and a 2-D model of through-the-thickness cross-section. All models were subjected to a progressive cool down from 1300oC to room temperature. Mudflat crack damage in the coating system resulted from the buildup of residual tensile stresses between the individual material constituents from thermal expansion mismatch. A 2-parameter Weibull distribution characterized the coating layer stochastic strength response and the effect of the Weibull modulus on the formation of damage was studied here.

residual tensile stress↗
NASA NTRS2018

Weibull-Based Stochastic Simulation of Mud-Crack Damage Formation in an Environmental Barrier Coating

The integrated Finite Element Analysis Micromechanics Analysis Code/Ceramics Analysis and Reliability Evaluation of Structures (FEAMAC/CARES) program was used to simulate the formation of mudflat-cracks from thermomechanical loading on a multi-layered Environmental Barrier Coating (EBC) system deposited on a ceramic substrate. FEAMAC/CARES combines MAC/GMC (Micromechanics Analysis Code/Generalized Method of Cells) multiscale composite micromechanics code with CARES/Life probabilistic multiaxial failure criteria code and Abaqusfinite element analysis. In this work, step function elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio finite elements enabled the depiction of crack boundaries and formation of mudflat patterned damage. Demonstrated examples include finite element models of button-sized disk-shaped 3-D specimen, and a 2-D model of through-the-thickness cross-section. All models were subjected to a progressive cool down from 1300 degrees Centigrade to room temperature. Mudflat crack damage in the coating system resulted from the buildup of residual tensile stresses between the individual material constituents from thermal expansion mismatch. A 2-parameter Weibull distribution characterized the coating layer stochastic strength response and the effect of the Weibull modulus on the formation of damage was studied here.

Residual Tensile Stress↗
NASA NTRS2018

Mechanoresponsive Healing Polymers

Methods are provided to produce new mechanoresponsive healing systems. Additionally, various embodiments provide a two tier self-healing material system concept that provides a non-intrusive method to mitigate impact damage in a structure ranging from low velocity impact damage (e.g., crack damage) to high velocity impact damage (e.g., ballistic damage.) The various embodiments provide the mechanophore linked polymer PBG-BCB-PBG. The various embodiments provide methods for synthesizing PBG-BCB-PBG.

Gordon, Keith L.↗
NASA NTRS1989

Damage analysis of a crack layer

Damage analysis of a crack layer in polystyrene is carried out by employing optical microscopy and principles of quantitative stereology. The results show that, within the quasistatic phase of crack layer propagation, the average crazing density, along the trailing edge of the active zone, is constant. This is consistent with a self-similarity hypothesis of damage evolution employed by the crack layer theory. The average crazing densities within the active zone and along its trailing edge are found to be practically equal. A layer of constant crazing density, adjacent to the crack planes, accompanies the crack during its quasi-static growth. This suggests that: (1) a certain level of crazing density should be reached, around the crack tip, prior to crack advance; (2) the specific energy, associated with this 'core' of damage, could be considered as a Griffith's type energy. The results are in favor of certain hypothesis adopted by the crack layer theory.

Botsis, J.↗
NASA NTRS2010

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 C and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3mm. Single-sided NDE methods were used because they might be practical for on-wing inspection, while X-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally cracked coating and subsequent oxidation damage was also studied with X-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.↗
NASA NTRS2009

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon (RCC)

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.↗
NASA NTRS1992

Environmental fatigue of an Al-Li-Cu alloy. Part 3: Modeling of crack tip hydrogen damage

Environmental fatigue crack propagation rates and microscopic damage modes in Al-Li-Cu alloy 2090 (Parts 1 and 2) are described by a crack tip process zone model based on hydrogen embrittlement. Da/dN sub ENV equates to discontinuous crack advance over a distance, delta a, determined by dislocation transport of dissolved hydrogen at plastic strains above a critical value; and to the number of load cycles, delta N, required to hydrogenate process zone trap sites that fracture according to a local hydrogen concentration-tensile stress criterion. Transgranular (100) cracking occurs for process zones smaller than the subgrain size, and due to lattice decohesion or hydride formation. Intersubgranular cracking dominates when the process zone encompasses one or more subgrains so that dislocation transport provides hydrogen to strong boundary trapping sites. Multi-sloped log da/dN-log delta K behavior is produced by process zone plastic strain-hydrogen-microstructure interactions, and is determined by the DK dependent rates and proportions of each parallel cracking mode. Absolute values of the exponents and the preexponential coefficients are not predictable; however, fractographic measurements theta sub i coupled with fatigue crack propagation data for alloy 2090 established that the process zone model correctly describes fatigue crack propagation kinetics. Crack surface films hinder hydrogen uptake and reduce da/dN and alter the proportions of each fatigue crack propagation mode.

Piascik, Robert S.↗
NASA NTRS1984

Tensile strength of composite sheets with unidirectional stringers and crack-like damage

The damage tolerance characteristics of metal tension panels with riveted and bonded stringers are well known. The stringers arrest unstable cracks and retard propagation of fatigue cracks. Residual strengths and fatigue lives are considerably greater than those of unstiffened or integrally stiffened sheets. The damage tolerance of composite sheets with bonded composite stringers loaded in tension was determined. Cracks in composites do not readily propagate in fatigue, at least not through fibers. Moreover, the residual strength of notched composites is sometimes even increased by fatigue loading. Therefore, the residual strength aspect of damage tolerance, and not fatigue crack propagation, was investigated. About 50 graphite/epoxy composite panels were made with two sheet layups and several stringer configurations. Crack-like slots were cut in the middle of the panels to simulate damage. The panels were instrumented and monotonically loaded in tension to failure. The tests indicate that the composite panels have considerable damage tolerance, much like metal panels. The stringers arrested cracks that ran from the crack-like slots, and the residual strengths were considerably greater than those of unstiffened composite sheets. A stress intensity factor analysis was developed to predict the failing strains of the stiffened panels. Using the analysis, a single design curve was produced for composite sheets with bonded stringers of any configuration.

Poe, C. C., Jr.↗
NASA NTRS1984

Tensile strength of composite sheets with unidirectional stringers and crack-like damage: A brief report

The residual strength of composite sheets with bonded composite stringers loaded in tension was determined. The results are summarized. About 50 graphite/epoxy composite panels with crack-like slots were monotonically loaded in tension to failure. Both sheet layup and stringer configuration were varied. The composite panels have considerable damage tolerance. The stringers arrested cracks that ran from the crack-like slots, and the residual strengths were considerably greater than those of unstiffened composite sheets. A stress-intensity factor analysis was developed to predict the failing strains of the stiffened panels. Using the analysis, a single design curve was produced for composite sheets with bonded stringers of any configuration.

Poe, C. C., Jr.↗
NASA NTRS1998

Fracture Analysis of the FAA/NASA Wide Stiffened Panels

This paper presents the fracture analyses conducted on the FAA/NASA stiffened and unstiffened panels using the STAGS (STructural Analysis of General Shells) code with the critical crack-tip-opening angle (CTOA) fracture criterion. The STAGS code with the "plane-strain" core option was used in all analyses. Previous analyses of wide, flat panels have shown that the high-constraint conditions around a crack front, like plane strain, has to be modeled in order for the critical CTOA fracture criterion to predict wide panel failures from small laboratory tests. In the present study, the critical CTOA value was determined from a wide (unstiffened) panel with anti-buckling guides. The plane-strain core size was estimated from previous fracture analyses and was equal to about the sheet thickness. Rivet flexibility and stiffener failure was based on methods and criteria, like that currently used in industry. STAGS and the CTOA criterion were used to predict load-against-crack extension for the wide panels with a single crack and multiple-site damage cracking at many adjacent rivet holes. Analyses were able to predict stable crack growth and residual strength with a few percent (5%) of stiffened panel tests results but over predicted the buckling failure load on a unstiffened panel with a single crack by 10%.

Seshadri, B. R.↗
NASA NTRS1999

Fracture Analysis of the FAA/NASA Wide Stiffened Panels

This paper presents the fracture analyses conducted on the FAA/NASA stiffened and unstiffened panels using the STAGS (STructural Analysis of General Shells) code with the critical crack-tip-opening angle (CTOA) fracture criterion. The STAGS code with the "plane-strain" core option was used in all analyses. Previous analyses of wide, flat panels have shown that the high-constraint conditions around a crack front, like plane strain, has to be modeled in order for the critical CTOA fracture criterion to predict wide panel failures from small laboratory tests. In the present study, the critical CTOA value was determined from a wide (unstiffened) panel with anti-buckling guides. The plane-strain core size was estimated from previous fracture analyses and was equal to about the sheet thickness. Rivet flexibility and stiffener failure was based on methods and criteria, like that currently used in industry. STAGS and the CTOA criterion were used to predict load-against-crack extension for the wide panels with a single crack and multiple-site damage cracking at many adjacent rivet holes. Analyses were able to predict stable crack growth and residual strength within a few percent (5%) of stiffened panel tests results but over predicted the buckling failure load on an unstiffened panel with a single crack by 10%.

Seshadri, B. R.↗
NASA NTRS1994

Fatigue life until small cracks in aircraft structures: Durability and damage tolerance

Crack initiation in notched elements occurs very early in the fatigue life. This is also true for riveted lap joints, an important fatigue critical element of a pressurized fuselage structure. Crack nucleation in a riveted lap joint can occur at different locations, depending on the riveting operation. It can occur at the edge of the rivet hole, at a small distance away from the hole, but still with subsequent crack growth through the hole, and ahead of the hole with a crack no longer passing through the hole. Moreover, crack nucleation can occur in the top row at the countersunk holes (outer sheet) or in the bottom row at the non-countersunk holes. Fractographic evidence is shown. The initial growth of the small cracks occurs as an (invisible) part through crack. As a consequence, predictions on the crack initiation life are problematic. After a though crack is present, the major part of the fatigue life has been consumed. There is still an apparent lack of empirical data on crack growth and residual strength of riveted lap joints, five years after the Aloha accident. Such data are very much necessary for further developments of prediction models. Some test results are presented.

Schijve, J.↗
NASA NTRS1994

Thermally induced damage in composite space structure: Predictive methodology and experimental correlation

A general analysis method is presented to predict matrix cracks in all plies of a composite laminate, and resulting degraded laminate properties, as functions of temperature or thermal cycles. A shear lag solution of the stresses in the vicinity of cracks and a fracture mechanics crack formation criteria are used to predict cracks. Damage is modeled incrementally, which allows the inclusion of the effects of temperature dependent material properties and softening of the laminate due to previous cracking. The analysis is incorporated into an easy-to-use computer program. The analysis is correlated with experimentally measured crack densities in a variety of laminates exposed to monotonically decreasing temperatures. Crack densities are measured at the edges of specimens by microscopic inspection, and throughout the specimen volumes by x-ray and sanding down of the edges. Correlation between the analytical results and the crack densities in the interiors of the specimens was quite good. Crack densities measured at specimen edges did not agree with internal crack densities (or analyses) in some cases. A free-edge stress analysis clarified the reasons for these discrepancies.

Park, Cecelia↗