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NASA NTRS2011

The Effects of Foam Thermal Protection System on the Damage Tolerance Characteristics of Composite Sandwich Structures for Launch Vehicles

For any structure composed of laminated composite materials, impact damage is one of the greatest risks and therefore most widely tested responses. Typically, impact damage testing and analysis assumes that a solid object comes into contact with the bare surface of the laminate (the outer ply). However, most launch vehicle structures will have a thermal protection system (TPS) covering the structure for the majority of its life. Thus, the impact response of the material with the TPS covering is the impact scenario of interest. In this study, laminates representative of the composite interstage structure for the Ares I launch vehicle were impact tested with and without the planned TPS covering, which consists of polyurethane foam. Response variables examined include maximum load of impact, damage size as detected by nondestructive evaluation techniques, and damage morphology and compression after impact strength. Results show that there is little difference between TPS covered and bare specimens, except the residual strength data is higher for TPS covered specimens.

Nettles, A. T.↗

NASA NTRS2001

On Multifunctional Collaborative Methods in Engineering Science

Multifunctional methodologies and analysis procedures are formulated for interfacing diverse subdomain idealizations including multi-fidelity modeling methods and multi-discipline analysis methods. These methods, based on the method of weighted residuals, ensure accurate compatibility of primary and secondary variables across the subdomain interfaces. Methods are developed using diverse mathematical modeling (i.e., finite difference and finite element methods) and multi-fidelity modeling among the subdomains. Several benchmark scalar-field and vector-field problems in engineering science are presented with extensions to multidisciplinary problems. Results for all problems presented are in overall good agreement with the exact analytical solution or the reference numerical solution. Based on the results, the integrated modeling approach using the finite element method for multi-fidelity discretization among the subdomains is identified as most robust. The multiple method approach is advantageous when interfacing diverse disciplines in which each of the method's strengths are utilized.

Ransom, Jonathan B.↗

NASA NTRS1999

Growth of Solid Solution Single Crystals

The solidification of a solid solution semiconductor, having a wide separation between liquidus and serious has been extensively studied in ground based, high magnetic field and Spacelab experiments. Two alloys of mercury cadmium telluride have been studied; mercury cadmium telluride with 80.0 mole percent of HgTe and 84.8 mole percent respectively. These alloys are extremely difficult to grow by directional solidification on earth due to high solutal and thermal density differences that give rise to fluid flow and consequent loss of interface shape and composition. Diffusion controlled growth is therefore impossible to achieve in conventional directional solidification. The ground based experiments consisted of growing crystals in several different configurations of heat pipe furnaces, NASA's Advanced Automated Directional Solidification Furnace (AADSF), and a similar furnace incorporated in a superconducting magnet capable of operating at up to 5T. The first microgravity experiment took place during the flight of STS-62 in March 1994, with the AADSF installed on the second United States Microgravity Payload (USMP-2). The alloy was solidified at 3/4 inch per day over a 9 day period, and for the first time a detailed evaluation was performed of residual acceleration effects. The second flight experiment took place in the fourth United States Microgravity Payload Mission (USMP-4) in November 1997. Due to contamination of the furnace system by a previously processed sample, the sample was not received until May 1998, and the preliminary analysis shows that the conditions prevailing during the experiment were quite different from the requirements requested prior to the mission. Early results are indicating that the sample may not accomplish the desired objectives. As with the USMP-2 mission, the results of the ground based experiments were compared with the crystal grown in orbit under microgravity conditions. On the earth, it has been demonstrated that the application of the magnetic field leads to a significant reduction in fluid flow, with improved homogeneity of composition. The field strength required to suppress flow increases with diameter of the material. The 8 mm diameter sample used here was less than the upper diameter limit for a ST magnet. The configuration for USMP-4 was changed so that the material was seeded and other processing techniques were also modified. It was decided to examine the effects of a strong magnetic field under the modified configuration and parameters. A further change from USMP-2 was that a different composition of material was grown, namely with 0.152 mole fraction of cadmium telluride rather than the 0.200 of the USMP-2 experiment. The objective was to grow highly homogeneous, low defect density material of a composition at which the conduction band and the valence band of the material impinge against each other. As indicated, the furnace was contaminated during the mission. As a result of solid debris remaining in the furnace bore, the cartridge in this experiment, denoted as SL1-417, was significantly bent during the insertion phase. During translation the cartridge scraped against the plate which isolates the hot and cold zones of the furnace. Thermocouples indicated that a thermal assymetry resulted. The scraping in the slow translation or crystal growth part of the processing was not smooth and it is probable that the jitter was sufficient to give rise to convection in the melt. Early measurements of composition from the surface of the sample have shown that the composition varies in an oscillatory manner.

Lehoczky, Sandor L.↗

NASA NTRS1981

Biaxial tests of flat graphite/epoxy laminates

The influence of biaxially applied loads on the strength of composite materials containing holes was analyzed. The analysis was performed through the development of a three dimensional, finite element computer program that is capable of evaluating fiber breakage, delamination, and matrix failure. Realistic failure criteria were established for each of the failure modes, and the influence of biaxial loading on damage accumulation under monotonically increasing loading was examined in detail. Both static and fatigue testing of specially designed biaxial specimens containing central holes were performed. Static tests were performed to obtain an understanding of the influence of biaxial loads on the fracture strength of composite materials and to provide correlation with the analytical predictions. The predicted distributions and types of damage are in reasonable agreement with the experimental results. A number of fatigue tests were performed to determine the influence of cyclic biaxial loads on the fatigue life and residual strength of several composite laminates.

Liebowitz, H.↗

NASA NTRS2009

Thermal Residual Stress in Environmental Barrier Coated Silicon Nitride - Modeled

When exposed to combustion environments containing moisture both un-reinforced and fiber reinforced silicon based ceramic materials tend to undergo surface recession. To avoid surface recession environmental barrier coating systems are required. However, due to differences in the elastic and thermal properties of the substrate and the environmental barrier coating, thermal residual stresses can be generated in the coated substrate. Depending on their magnitude and nature thermal residual stresses can have significant influence on the strength and fracture behavior of coated substrates. To determine the maximum residual stresses developed during deposition of the coatings, a finite element model (FEM) was developed. Using this model, the thermal residual stresses were predicted in silicon nitride substrates coated with three environmental coating systems namely barium strontium aluminum silicate (BSAS), rare earth mono silicate (REMS) and earth mono di-silicate (REDS). A parametric study was also conducted to determine the influence of coating layer thickness and material parameters on thermal residual stress. Results indicate that z-direction stresses in all three systems are small and negligible, but maximum in-plane stresses can be significant depending on the composition of the constituent layer and the distance from the substrate. The BSAS and REDS systems show much lower thermal residual stresses than REMS system. Parametric analysis indicates that in each system, the thermal residual stresses can be decreased with decreasing the modulus and thickness of the coating.

Ali, Abdul-Aziz↗

NASA NTRS2000

A Strip-Yield Model for Predicting the Growth of Part-Through Cracks Under Cyclic Loading

Flaws exist in aircraft structures due to manufacturing operations and material defects. Under variable amplitude cyclic loading, these flaws grow as part-through cracks reducing the residual strength of structural components. To meet damage tolerant design requirements, accurate flaw growth predictions are needed which account for continual changes in crack shape as well as crack growth retardation and acceleration. Predicting the growth of part-through cracks under cyclic loading using an innovative and computationally efficient model is the focus of the research summarized in this report. In this research effort, a slice synthesis methodology was developed and used to construct a modified strip-yield model for the part-through semi-elliptical surface flaw, enabling prediction of plasticity-induced closure along the crack front and subsequent fatigue crack growth under constant amplitude and variable amplitude loading. While modeling the plasticity-induced closure in a part-through flaw may be performed using three dimensional elastic-plastic finite element analysis, this type of effort is impractical from an engineering perspective. A modified strip-yield model similar to that used in FASTRAN for part-through flaws is a much needed engineering design tool, particularly when computational resources are limited.

Daniewicz, S. R.↗

NASA NTRSDate not supplied

Downwelling Far-Infrared Emission Spectra Measured by FIRST at Cerro Toco, Chile and Table Mountain Facility, CA

The Far-Infrared Spectroscopy of the Troposphere (FIRST) instrument is a fourier transform spectrometer developed to measure the far-infrared portion of the Earth's longwave spectrum. Specifically, the purpose is measurement of the important, yet under-investigated 100 to 1000 cm-1 band. Presented here are measurements made by FIRST at two successful deployments in a ground-based configuration to measure downwelling longwave radiation. The initial deployment was to Cerro Toco, Chile. FIRST operated from August to October, 2009 as part of the Radiative Heating in Underexplored Bands Campaign (RHUBC-II) campaign. After recalibration, FIRST was deployed to the Table Mountain Facility from August to October, 2012. Dry days for both campaigns were chosen for analysis ? 09/24/2009 and 10/19/2012. Also available from both deployments are coincident radiosonde temperature and water vapor vertical profiles used as inputs to radiance calculations performed by two platforms, the AER Line-by-Line Radiative Transform Model (using the AER line database), and a research platform, MRTA utilizing HITRAN 2012. Thus, we have three streams of data for the closure studies, and results of the comparisons are presented showing good agreement in the optically thick regions of 200-400 cm-1 and 600-800 cm-1. Differences between measured and coincident calculated spectra between 400 and 600 cm-1 are less than 10 mW/m^2/sr/cm-1. Uncertainties accounted for in this study include uncertainty from multiple detectors, water vapor, temperature, line strength and width as presented in HITRAN 2012, and due to internal heating caused by black bodies. The residuals fall within the root-sum-square envelope of the uncertainties.

J Mast↗

NASA NTRS2020

Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating

The FEAMAC/CARES program, which integrates finite element analysis (FEA) with the MAC/GMC (Micromechanics Analysis Code with Generalized Method of Cells) and the CARES/Life (Ceramics Analysis and Reliability Evaluation of Structures / Life Prediction) programs, was used to simulate the formation of mudcracks during the cooling of a multilayered environmental barrier coating (EBC) deposited on a silicon carbide substrate. FEAMAC/CARES combines the MAC/GMC multiscale micromechanics analysis capability (primarily developed for composite materials) with the CARES/Life probabilistic multiaxial failure criteria (developed for brittle ceramic materials) and Abaqus (Dassault Systèmes) FEA. In this report, elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio elements enabled the formation of crack boundaries, leading to development of mudcrack-patterned damage. Finite element models of a disk-shaped three-dimensional specimen and a twodimensional model of a through-the-thickness cross section subjected to progressive cooling from 1,300 °C to an ambient temperature of 23 °C were made. Mudcrack damage in the coating resulted from the buildup of residual tensile stresses between the individual material constituents because of thermal expansion mismatches between coating layers and the substrate. A two-parameter Weibull distribution characterized the coating layer stochastic strength response and allowed the effect of the Weibull modulus on the formation of damage and crack segmentation lengths to be studied. The spontaneous initiation of cracking and crack coalescence resulted in progressively smaller mudcrack cells as cooling progressed, consistent with a fractal-behaved fracture pattern. Other failure modes such as delamination, and possibly spallation, could also be reproduced. The physical basis assumed and the heuristic approach employed, which involves a simple stochastic cellular automaton methodology to approximate the crack growth process, are described. The results ultimately show that a selforganizing mudcrack formation can derive from a Weibull distribution that is used to describe the stochastic strength response of the bulk brittle ceramic material layers of an EBC.

Nemeth, Noel N.↗

NASA NTRS1999

Influence of Transport on Two-Dimensional Model Simulation: 2. Stratospheric Aircraft Perturbations: Stratospheric Aircraft Perturbations - 2

We have adopted the transport scenarios used in Part 1 to examine the sensitivity of stratospheric aircraft perturbations to transport changes in our 2-D model. Changes to the strength of the residual circulation in the upper troposphere and stratosphere and changes to the lower stratospheric K(sub zz) had similar effects in that increasing the transport rates decreased the overall stratospheric residence time and reduced the magnitude of the negative perturbation response in total ozone. Increasing the stratospheric K(sub yy) increased the residence time and enhanced the global scale negative total ozone response. However, increasing K(sub yy) along with self-consistent increases in the corresponding planetary wave drive, which leads to a stronger residual circulation, more than compensates for the K(sub yy)-effect, and results in a significantly weaker perturbation response, relative to the base case, throughout the stratosphere. We found a relatively minor model perturbation response sensitivity to the magnitude of K(sub yy) in the tropical stratosphere, and only a very small sensitivity to the magnitude of the horizontal mixing across the tropopause and to the strength of the mesospheric gravity wave drag and diffusion. These transport simulations also revealed a generally strong correlation between passive NO(sub y) accumulation and age of air throughout the stratosphere, such that faster transport rates resulted in a younger mean age and a smaller NO(y) mass accumulation. However, specific variations in K(sub yy) and mesospheric gravity wave strength exhibited very little NO(sub y)-age correlation in the lower stratosphere, similar to 3-D model simulations performed in the recent NASA "Models and Measurements" II analysis. The base model transport, which gives the most favorable overall comparison with inert tracer observations, simulated a global/annual mean total ozone response of -0.59%, with only a slightly larger response in the northern compared to the southern hemisphere. For transport scenarios which gave tracer simulations within some agreement with measurements, the annual/globally averaged total ozone response ranged from -0.45% to -0.70%. Our previous 1995 model exhibited overly fast transport rates, resulting in a global/annually averaged perturbation total ozone response of -0.25%, which is significantly weaker compared to the 1999 model. This illustrates how transport deficiencies can bias model simulations of stratospheric aircraft.

Fleming, Eric L.↗

NASA NTRS2016

Latent Hardeners for the Assembly of Epoxy Composites

Large-scale composite structures are commonly joined by secondary bonding of molded-and-cured thermoset components. This approach may result in unpredictable joint strengths. In contrast, assemblies made by co-curing, although limited in size by the mold, result in stable structures, and are certifiable for commercial aviation because of structural continuity through the joints. Multifunctional epoxy resins were prepared that should produce fully-cured subcomponents with uncured joining surfaces, enabling them to be assembled by co-curing in a subsequent out-of-autoclave process. Aromatic diamines were protected by condensation with a ketone or aldehyde to form imines. Properties of the amine-cured epoxy were compared with those of commercially available thermosetting epoxy resins and rheology and thermal analysis were used to demonstrate the efficacy of imine protection. Optimum conditions to reverse the protecting chemistry in the solid state using moisture and acid catalysis were determined. Alternative chemistries were also investigated. For example, chain reaction depolymerization and photoinitiated catalysts would be expected to minimize liberation of volatile organic content upon deprotection and avoid residual reactive species that could damage the resin. Results from the analysis of protected and deprotected resins will be presented.

Palmieri, Frank↗

NASA NTRS1993

Modeling of PCG fluid dynamics: Salient results

Materials processing in space-based laboratories has already yielded higher quality crystals during previous space flights, and opportunities for several fluids experiments are anticipated during the extended duration missions planned for the future. Crystal growth in space benefits not only from its reduced gravity environment but also from the absence of the hydrostatic pressure which assists certain crystal growth and refinement methods. Gravity-driven phenomena are thus reduced in strength, and a purely diffusive fluid's behavior can be attained. In addition, past materials science experiments have shown that microgravity can also help produce larger crystals. While gravity-related effects are definitely curtailed in space, they are nevertheless present to some degree due to the acceleration environment onboard the spacecraft. This residual acceleration level is comprised of quasi-steady, oscillatory, and transient components, and is caused by a variety of mechanisms. For example, gravity gradient forces produce low frequency disturbances, and the operation of machinery, control thrusters, solar panels, human activity, etc. contribute to higher frequency accelerations. These disturbances are collectively referred to as g-jitter, and they can be deleterious to certain experiments where the minimization of the acceleration level is important. Advanced vibration isolation techniques can be utilized to actively filter out some of the detrimental frequencies and help in obtaining optimum results. However, the successful application of this technology requires the detailed analysis of candidate fluids experiments to gauge their response to g-jitter and to determine their acceleration sensitivities. Several crystal growth experiments in the Protein Crystal Growth (PCG) area, besides others, are expected to be carried out on future shuttle flights and on Space Station Freedom. The need for vibration isolation systems or components for microgravity science experiments can be expected to grow as experiments and available hardware becomes more complex. This technology will also find increased application as the science community develops an awareness of their specific needs relative to the environment available in manned space missions. Vibration isolation research strives to develop a microgravity environment requirement that defines tolerance limits on the allowable g-level, and provides the required technology to achieve it. This effort will assist in establishing the tolerable acceleration levels for specific fluids experiments. The primary effort is directed towards modeling PCG and the approach undertaken for this investigation is outlined. The objectives of this research are: (1) to computationally determine vibration sensitivity of protein crystal growth experiments; (2) determine if these experiments can benefit from vibration isolation techniques; and (3) provide realistic requirements for vibration isolation technology.

Ramachandran, N.↗

NASA NTRS2011

Advanced Gear Alloys for Ultra High Strength Applications

Single tooth bending fatigue (STBF) test data of UHS Ferrium C61 and C64 alloys are presented in comparison with historical test data of conventional gear steels (9310 and Pyrowear 53) with comparable statistical analysis methods. Pitting and scoring tests of C61 and C64 are works in progress. Boeing statistical analysis of STBF test data for the four gear steels (C61, C64, 9310 and Pyrowear 53) indicates that the UHS grades exhibit increases in fatigue strength in the low cycle fatigue (LCF) regime. In the high cycle fatigue (HCF) regime, the UHS steels exhibit better mean fatigue strength endurance limit behavior (particularly as compared to Pyrowear 53). However, due to considerable scatter in the UHS test data, the anticipated overall benefits of the UHS grades in bending fatigue have not been fully demonstrated. Based on all the test data and on Boeing s analysis, C61 has been selected by Boeing as the gear steel for the final ERDS demonstrator test gearboxes. In terms of potential follow-up work, detailed physics-based, micromechanical analysis and modeling of the fatigue data would allow for a better understanding of the causes of the experimental scatter, and of the transition from high-stress LCF (surface-dominated) to low-stress HCF (subsurface-dominated) fatigue failure. Additional STBF test data and failure analysis work, particularly in the HCF regime and around the endurance limit stress, could allow for better statistical confidence and could reduce the observed effects of experimental test scatter. Finally, the need for further optimization of the residual compressive stress profiles of the UHS steels (resulting from carburization and peening) is noted, particularly for the case of the higher hardness C64 material.

Shen, Tony↗

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 NTRS1999

The interstellar 4.62 micron band

We present new 4.5-5.1 micron (2210-1970 cm-1) spectra of embedded protostars, W33 A, AFGL 961 E, AFGL 2136, NGC 7538 IRS 9, and Mon R2 IRS 2, which contain a broad absorption feature located near 4.62 micron (2165 cm-1), commonly referred to in the literature as the "X-C triple bond N" band. The observed peak positions and widths of the interstellar band agree to within 2.5 cm-1 and 5 cm-1, respectively. The strengths of the interstellar 4.62 micrometers band and the ice absorption features in these spectra are not correlated, which suggests a diversity of environmental conditions for the ices we are observing. We explore several possible carriers of the interstellar band and review possible production pathways through far-ultraviolet photolysis (FUV), ion bombardment of interstellar ice analog mixtures, and acid-base reactions. Good fits to the interstellar spectra are obtained with an organic residue produced through ion bombardment of nitrogen-containing ices or with the OCN- ion produced either through acid-base reactions or FUV photolysis of NH3-containing ices.

NASA Center ARC↗

NASA NTRS2003

Effects of Impact Damage in Midplane Asymmetric Sandwich Composites

Several structural sandwich composites arc in service on military and commercial aerospace vehicles, however, these components have been limited to secondary structures partly because the impact damage and damage tolerance of these composites have not been extensively characterized. To improve durability, safety, and life cycle performance of PMCs while reducing maintenance costs, combined analysis, and test methods that provide a means of predicting critical engineering properties after impact damage of the structure, must be developed. A key enabling technology here is the establishment of the correlation between the impact test results conducted in the laboratory and the mechanics-based phenomenological solutions. This research was undertaken to investigate the compression and flexural properties following low velocity impact of a nomex/phenolic honeycomb core, fiberglass/epoxy facesheet, midplane asymmetric sandwich composite. One facesheet (thin side) was composed of two plies of the fiberglass/epoxy (0/90), while the other facesheet (thick side) was composed of four plies (0/90/0/90) of fiberglass/epoxy. Due to the differences in facesheet thickness, impact damage was separately induced on the thick side as well as the thin side. The compression and flexural strength properties for each damage arrangement were compared using different levels of impact energy ranging from 0 to 452 Joules. In all cases, higher impact energy resulted in decreased compression and flexural strength. Impact on the thin side showed slightly more retention of compression strength at low impact levels, whereas higher residual compressive strength was observed from impact on the thick side at higher impact levels. Different facesheet thicknesses or midplane asymmetry, played an important role in the flexural strength, however, low velocity impact on the both the thick and thin fiberglass/epoxy facesheet side showed an almost linear loss of flexural strength to saturation.

Meador, Michael↗

NASA NTRS2001

Thermal Processing Effects on the Adhesive Strength of PS304 High Temperature Solid Lubricant Coatings

In this paper the effects of post deposition heat treatments on the cohesive and adhesive strength properties of PS304, a plasma sprayed nickel-chrome based, high temperature solid lubricant coating deposited on stainless steel, are studied. Plasma spray deposited coating samples were exposed in air at temperatures from 432 to 650 C for up to 500 hr to promote residual stress relief, enhance particle to particle bonding and increase coating to substrate bond strength. Coating pull-off strength was measured using a commercial adhesion tester that utilizes 13 mm diameter aluminum pull studs attached to the coating surface with epoxy. Pull off force was automatically recorded and converted to coating pull off strength. As deposited coating samples were also tested as a baseline. The as-deposited (untreated) samples either delaminated at the coating-substrate interface or failed internally (cohesive failure) at about 17 MPa. Samples heat treated at temperatures above 540 C for 100 hr or at 600 C or above for more than 24 hr exhibited strengths above 31 MPa, nearly a two fold increase. Coating failure occurred inside the body of the coating (cohesive failure) for nearly all of the heat-treated samples and only occasionally at the coating substrate interface (adhesive failure). Metallographic analyses of heat-treated coatings indicate that the Nickel-Chromium binder in the PS304 appears to have segregated into two phases, a high nickel matrix phase and a high chromium precipitated phase. Analysis of the precipitates indicates the presence of silicon, a constituent of a flow enhancing additive in the commercial NiCr powder. The exact nature and structure of the precipitate phase is not known. This microstructural change is believed to be partially responsible for the coating strength increase. Diffusion bonding between particles may also be playing a role. Increasing the heat treatment temperature, exposure time or both accelerate the heat treatment process. Preliminary measurements indicate that the heat treatment also results in a one time, permanent coating thickness increase of about 3%. Based upon these results, the incorporation of a heat treatment prior to final finishing has been incorporated in the application process of this coating technology.

DellaCorte, Christopher↗

NASA NTRS2011

2014/2219 Tri-Point Crack Analysis

Friction stir welding (FSW) is a solid state welding process with potential advantages for aerospace and automotive industries dealing with light alloys. Self-reacting friction stir welding (SR-FSW) is one variation of the FSW process being developed at the National Aeronautics and Space Administration (NASA) for use in the fabrication of propellant tanks. Friction plug welding is used to seal the exit hole that remains in a circumferential SR-FSW. The objective of this study was to evaluate the deformation response at the tips of cracks located in the heat affected zone of friction plug welds and to study the fracture behavior of welds with defects in the form of fatigue cracks. The study used existing 2014-T6 to 2219-T87 self-reacting friction stir weld panels with 2219-T87 friction plug welds. Electro-discharge machined (EDM) notches were machined into the heat affected zone of the plug at the plug-to-base metal interface. Samples were then cycled to generate a fatigue crack emanating from the notch. After the fatigue crack reached a pre-defined length, a speckle pattern was applied and the ARAMIS system (a three dimensional imaging correlation system) was used to measure the deformations at the crack tip under a sequence of loads. Testing was conducted at ambient laboratory conditions. Fracture data from the testing was analyzed to evaluate residual strength capability of the panel as a function of flaw size. ARAMIS strain data was evaluated to examine strain and deformation patterns that develop around the crack tip and at the plug/weld interfaces. Four samples were used in this study, with three samples in a post-weld heat treated condition. Three samples contained large diameter plugs (M5) and one sample contained a small diameter plug (M3). Two samples were 4 inches in width and two samples were 8.5 inches in width. All samples failed through the precrack with residual strengths ranging from 37 ksi to 42 ksi.

Horton, Karla Renee↗