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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.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

Porosity Detection and Localization During Composite Cure Inside an Autoclave Using Ultrasonic Inspection

Composite materials offer unique benefits in aerospace applications such as increased strength-to-weight ratio and improved fatigue properties. They are increasingly being used in major commercial aircraft programs. However, current processing methods can lead to defects in composite parts, which must be detected using post-manufacturing inspection methods. Porosity (i.e., pores, voids) is a critical defect from the cure process that is detrimental to performance of the composite part. It is therefore necessary to understand and eliminate the formation of porosity defects. At NASA Langley Research Center, an in-situ cure monitoring system was developed to detect porosity defects as they form in real-time inside an autoclave. A capability to directly detect and localize porosity within a composite during cure did not exist before. This study is focused on an elevated-temperature ultrasonic inspection system to detect porosity defects in composites during autoclave cure. The ultrasonic inspection system operated inside an autoclave within an enclosure cooled by intermittent liquid nitrogen (LN_2) injections. A high-temperature, 2.25 MHz, transducer transmitted ultrasonic waves through the tool plate and into the composite part and measured the amplitude and time of flight of the reflected waves with a 1 mm × 1 mm step size/areal resolution. Porosity was observed via the ultrasonic reflections, which experienced increased attenuation in regions of high porosity. Distinct regions of increased porosity were present due to uneven pressure across the panel, which was driven by an intentional misfit between the flat caul plate and the tapered composite panel with ply drops. The results were validated by post-cure ultrasonic inspection and micrographs. The in-situ inspection system was able to successfully provide porosity detection and localization in the tapered ply-drop panel. The successful results indicate the promise of this system for future implementation in the manufacturing of composite structures for aerospace applications.

Composites↗
NASA NTRSDate not supplied

ASTM International Conference on Additive Manufacturing – 2022

The In-Situ Project: Correlating In-situ monitoring data and Non-Destructive Evaluation (NDE) methods to characterize defect populations in Laser Powder Bed Fusion (L-PBF) material NDE is critical to enable the safe use of additive manufactured (AM) parts in aerospace applications. However, traditional NDE methods are not fully adaptable to complex AM geometries to appropriately screen for critical defects, and L-PBF processes inherently generate defects. In-situ monitoring techniques can give information about the quality of the build process and indicate process variations that could potentially create defects. Proven, causal correlations between in-situ monitoring indications and resulting defects are needed to inform about the final quality of the part. Thus, the development of a new approach is necessary. NASA started a two-phase study that would investigate techniques for characterizing defect populations in L-PBF material, first in material with induced defects, then in a nominal L-PBF process, by correlating in-situ, NDE, and serial sectioning data. Objectives also include the evaluation of seeded defect methodologies for realistic defect creation, creating a baseline of defect populations in a Qualified Material Process (QMP), characterizing the effect of heat treatment, and correlating defect populations with tensile and fatigue properties. By comparing computed tomography images, in-situ monitoring images, and metallography images, the team has been able to draw preliminary conclusions. They include a better understanding of the limitation of the NDE tools, learning about the “healing” of the samples observed during layer building and a comparison study on different laser power variation samples. Those preliminary conclusions will help dictate the follow-up work that will be presented at the conference.

additive manufacturing↗
NASA NTRS1985

Effect of low temperature on fatigue and fracture properties of Ti-5Al-2.5Sn(ELI) for use in engine components

Experiments were conducted to evaluate the characteristics of the Ti-5Al-2.5Sn (ELI) alloy used in a fuel pump impeller at cryogenic temperatures. Tension, fracture toughness, and fatigue crack propagation data were collected determining the effect of frequency and load ratio on crack propagation. The results revealed that tensile strength increased significantly at 20 K compared to room temperature and fracture toughness was reduced at cryogenic temperatures. The fatigue crack growth rate was not sensitive to experimental conditions and there were only minimal crack orientation effects. Different frequencies produced no effect. At various temperatures and frequencies a load ratio increase resulted in higher crack growth rates. At low stress intensity levels the fatigue rate for both temperatures was the same; however, at high stress intensity levels the crack growth rate at 20 K increased because of the decrease in fracture toughness. The results correlated well with previous data.

Ryder, J. T.↗
NASA NTRS1976

Fatigue of notched fiber composite laminates. Part 2: Analytical and experimental evaluation

The analytical/experimental correlation study was performed to develop an understanding of the behavior of notched Boron/epoxy laminates subjected to tension/tension fatigue loading. It is postulated that the fatigue induced property changes (stiffness as well as strength) of the laminate can be obtained from the lamina fatigue properties. To that end, the Boron/epoxy lamina static and fatigue data (lifetime, residual stiffness and strength) were obtained initially. The longitudinal and transverse tension data were determined from the (0) and (90) laminate tests while the in-plane shear data were obtained from the (+ or - 45) sub s laminates. The static tests obtained the notched strength and mode of failure while the fatigue tests determined lifetime, damage propagation and residual strength. The failure in static tension occurred in a transverse crack propagation mode.

Kulkarni, S. V.↗
DOE OSTI2020

Build orientation, surface roughness, and scan path influence on the microstructure, mechanical properties, and flexural fatigue behavior of Ti–6Al–4V fabricated by electron beam melting

In the present work, microstructure and fatigue behavior of Electron Beam Melted (EBM) Ti–6Al–4V have been systematically studied. Fatigue behavior was investigated using four-point bend tests of rectangular bars with internal features fabricated with different build orientations, scan paths, and surface conditions. Microstructural variations were evaluated by optical microscopy and Vickers micro-hardness indentations, both of which were found to be consistent throughout the build and within ranges reported in the literature. The fatigue performance of the EBM material was comparable to wrought Ti–6Al–4V when the loading direction was parallel to the build direction, but severely limited when loaded perpendicular to the build direction or if surface roughness defects were present. Scanning electron microscopy and interrupted fatigue tests were utilized to characterize fracture surfaces, failure mechanisms, crack initiation, and propagation behavior. Crack initiation sites in the vertically-oriented specimens were identified to be melt-related defects formed by insufficient melting.

36 MATERIALS SCIENCE↗
NASA NTRS1976

YF-12 Lockalloy ventral fin program, volume 1

Results are presented of the YF-12 Lockalloy Ventral Fin Program which was carried out by Lockheed Aircraft Corporation - Advanced Development Projects for the joint NASA/USAF YF-12 Project. The primary purpose of the program was to redesign and fabricate the ventral fin of the YF-12 research airplane (to reduce flutter) using Lockalloy, and alloy of beryllium and aluminum, as a major structural material. A secondary purpose, was to make a material characterization study (thermodynamic properties, corrosion; fatigue tests, mechanical properties) of Lockalloy to validate the design of the ventral fin and expand the existing data base on this material. All significant information pertinent to the design and fabrication of the ventral fin is covered. Emphasis throughout is given to Lockalloy fabrication and machining techniques and attendant personnel safety precautions. Costs are also examined. Photographs of tested alloy specimens are shown along with the test equipment used.

Duba, R. J.↗
NASA NTRS1979

Strainrange partitioning life predictions of the long time metal properties council creep-fatigue tests

The method of strainrange partitioning is used to predict the cyclic lives of the Metal Properties Council's long time creep-fatigue interspersion tests of several steel alloys. Comparisons are made with predictions based upon the time- and cycle-fraction approach. The method of strainrange partitioning is shown to give consistently more accurate predictions of cyclic life than is given by the time- and cycle-fraction approach.

Saltsman, J. F.↗
NASA NTRS1979

Strainrange partitioning life predictions of the long time Metal Properties Council creep-fatigue tests

The method of Strainrange Partitioning is used to predict the cyclic lives of the Metal Properties Council's long time creep-fatigue interspersion tests of several steel alloys. Comparisons are made with predictions based upon the Time- and Cycle-Fraction approach. The method of Strainrange Partitioning is shown to give consistently more accurate predictions of cyclic life than is given by the Time- and Cycle-Fraction approach.

Saltsman, J. F.↗
NASA NTRS1991

The effects of multiple repairs on Inconel 718 weld mechanical properties

Inconel 718 weldments were repaired 3, 6, 9, and 13 times using the gas tungsten arc welding process. The welded panels were machined into mechanical test specimens, postweld heat treated, and nondestructively tested. Tensile properties and high cycle fatigue life were evaluated and the results compared to unrepaired weld properties. Mechanical property data were analyzed using the statistical methods of difference in means for tensile properties and difference in log means and Weibull analysis for high cycle fatigue properties. Statistical analysis performed on the data did not show a significant decrease in tensile or high cycle fatigue properties due to the repeated repairs. Some degradation was observed in all properties, however, it was minimal.

Russell, C. K.↗
NASA NTRS1991

The effect of matrix mechanical properties on (0)8 unidirectional SiC/Ti composite fatigue resistance

The relationship between constituent and MMC properties in fatigue loading is investigated with low-cycle fatigue-resistance testing of an alloy Ti-15-3 matrix reinforced with SiC SCS-6 fibers. The fabrication of the composite is described, and specimens are generated that are weak and ductile (WD), strong and moderately ductile (SM), or strong and brittle (SB). Strain is measured during MMC fatigue tests at a constant load amplitude with a load-controlled waveform and during matrix-alloy fatigue tests at a constant strain amplitude using a strain-controlled waveform. The fatigue resistance of the (0)8 SiC/Ti-15-3 composite is found to be slightly influenced by matrix mechanical properties, and the composite- and matrix-alloy fatigue lives are not correlated. This finding is suggested to relate to the different crack-initiation and -growth processes in MMCs and matrix alloys.

Gabb, T. P.↗
NASA NTRS1986

Orientation and temperature dependence of some mechanical properties of the single-crystal nickel-base superalloy Rene N4. II - Low cycle fatigue behavior

The low cycle fatigue (LCF) properties of a single-crystal nickel-base superalloy Rene N4, have been examined at 760 and 980 C in air. Specimens having crystallographic orientations near the 001, 011, -111, 023, -236, and -145 lines were tested in fully reversed, total-strain-controlled LCF tests at a frequency of 0.1 Hz. At 760 C, this alloy exhibited orientation dependent tension-compression anisotropies of yielding which continued to failure. Also at 760 C, orientations exhibiting predominately single slip exhibited serrated yielding for many cycles. At 980 C, orientation dependencies of yielding behavior were smaller. In spite of the tension-compression anisotropies, cyclic stress range-strain range behavior was not strongly orientation dependent for either test temperature. Fatigue life on a total strain range basis was highly orientation dependent at 760 and 980 C and was related chiefly to elastic modulus, low modulus orientations having longer lives. Stage I crack growth on 111 planes was dominant at 760 C, while Stage II crack growth occurred at 980 C. Crack initiation generally occurred at near-surface micropores, but occasionally at oxidation spikes in the 980 C tests.

Gabb, T. P.↗
NASA NTRS1977

Consideration of encapsulants for photovoltaic arrays in terrestrial applications

Long-term survivability of photovoltaic arrays and components in terrestrial environments will require development of adequate protective systems. Highly considered are polymeric encapsulants, a method which was successfully employed in space and aerospace applications to protect critical electrical circuitry. To be employable, however, the polymer encapsulants must themselves be chemically and mechanically resistant to failure in terrestrial service. Chemical resistance includes stability to the degrading actions of ultraviolet light, oxygen, moisture and elevated temperatures in sun rich areas. Programs are underway to identify and develop chemically stable encapsulant candidates. Chemical considerations aside, mechanical failures of the encapsulants must also be avoided in array designs. This paper discusses design considerations for avoiding mechanical failures of polymeric encapsulants, with emphasis on biaxial properties, thermal fatigue, and anisotropy and nonhomogeneity of material properties. The general principles to be presented evolved from actual failures of polymeric materials in engineering applications. Also included are brief remarks on the permeability of polymer materials to atmospheric gases.

Cuddihy, E. F.↗