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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Effect of macroscopic surface defects on dynamic damage: An experimental and numerical study

This study examines the impact of macroscopic surface defects on the dynamic ductile damage behavior of polycrystalline metals using plate-impact experiments. Defects of various shapes (flat, round, and point) were manufactured on the free or impact surfaces of annealed copper specimens. The experiments were diagnosed with photon Doppler velocimetry measurements and soft recovery techniques. The experimental results revealed that defect shape and location significantly affect velocity–time profiles and void distribution. In order to understand the dynamics of shock propagation and corresponding ductile damage evolution within the target specimens, the impact experiments were modeled with a calibrated Tepla model, a dynamic ductile damage model for polycrystalline metals [Nguyen et al., Int. J. Solids Struct. 329, 113833 (2026)]. Overall, our resulting simulated velocity showed good agreement with measured velocity, and our simulated porosity distributions qualitatively matched experimental data. Based on our simulation results, defects on the free surface were found to distort rarefaction waves and therefore the corresponding spall planes. On the other hand, defects on the impact surface generated a delayed shock when the flyer plate and the defected target area were in contact, leading to distortion of the spall plane. The distortion of the spall plane resulted in a non-uniform distribution of voids within the defected specimens. Lastly, we examined the role of local work hardening due to the defect manufacturing process on the velocity and porosity distribution, using Tepla simulations with a simplified representation of local hardening. This investigation highlights the importance of defect geometry, location, and local hardening associated with defect generation in dynamic ductile damage processes.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Relative Importance of Assumed Infrasound Source Terms and Effects of Atmospheric Models on the Linear Inversion of Infrasound Time Series at the Source Physics Experiment

We invert far-field infrasound data for the equivalent seismoacoustic time-domain moment tensor to assess the effects of variable atmospheric models and source phenomena. The infrasound data were produced by a series of underground chemical explosions that were conducted during the Source Physics Experiment (SPE), which was originally designed to study seismoacoustic signal phenomena. The first goal is to investigate the sensitivity of the inversion to the variability of the estimated atmospheric model. The second goal is to determine the relative contribution of two presumed source mechanisms to the observed infrasonic wavefield. Rather than using actual atmospheric observations to estimate the necessary atmospheric Green’s functions, we build a series of atmospheric models that rely on publicly available, regional-scale atmospheric observations. The atmospheric observations are summarized and interpolated onto a 3D grid to produce a model of sound speed at the time of the experiment. For each of four SPE acoustic datasets that we invert, we produced a suite of three atmospheric models for each chemical explosion event, based on 10 yrs of meteorological data: an average model, which averages the atmospheric conditions for 10 yrs prior to each SPE event, as well as two extrema models. To parameterize the inversion, we assume that the source of infrasonic energy results from the linear combination of explosion-induced surface spall and linear seismic-to-elastic mode conversion at the Earth’s free surface. We find that the inversion yields relatively repeatable results for the estimated spall source. Conversely, the estimated isotropic explosion source is highly variable. This suggests that 1) the majority of the observed acoustic energy is produced by the spall and/or 2) our modeling of the elastic energy, and the subsequent conversion to acoustic energy, is too simplistic.

58 GEOSCIENCES↗
DOE OSTI2018

The use of atmospheric prediction models to invert infrasound for linear-equivalent time domain moment tensors: Source Physics Experiment, Phase 1

We invert far field infrasound data for the equivalent seismo-acoustic time domain moment tensor to assess the effects of variable atmospheric models as well as to quantify the relative contributions of two presumed source phenomena. The infrasound data was produced by a series of underground chemical explosions that were conducted during the Source Physics Experiment, (SPE) which was originally designed to study explosion-generated seismo-acoustic signal phenomena. The goal of the work presented herein is two-fold: the first goal is to investigate the sensitivity of the estimated time domain moment tensors to variability of the estimated atmospheric model. The second goal is to determine the relative contribution of two possible source mechanisms to the observed infrasonic wave field. Rather than using actual atmospheric observations to estimate the necessary atmospheric Green's functions, we build a series of atmospheric models that rely on publicly available, regional atmospheric observations and the assumption that the acoustic energy results from a linear combination of an underground isotropic explosion and surface spall. The atmospheric observations are summarized and interpolated onto a 3D grid to produce a model of sound speed at the time of the experiment. For each of four SPE acoustic datasets that we invert, we produced a suite of three atmospheric models, based on ten years of regional meteorological observations: an average model, which averages the atmospheric conditions for ten years prior to each SPE event, as well as two extrema models. We find that the inversion yields relatively repeatable results for the estimated spall source. Conversely, the estimated isotropic explosion source is highly variable. This suggests that the majority of the observed acoustic energy is produced by the spall source and/or our modeling of the elastic energy propagation, and it's subsequent conversion to acoustic energy via linear elastic-to-acoustic coupling at the free surface, is too simplistic.

58 GEOSCIENCES↗
DOE OSTI2018

The Relative Importance of Assumed Infrasound Mechanisms on the Linear Inversion of Infrasound Time Series at the Source Physics Experiment

We invert far field infrasound data for the equivalent seismo-acoustic time domain moment tensor to assess the relative importance of two assumed seismoacoustic source mechanisms. The infrasound data were produced by a four of the underground chemical explosions that were conducted during the Source Physics Experiment (SPE). For each SPE event that we invert, we produce three set of atmospheric Green's functions: an average model based on ten years of atmospheric data, as well as two extrema models designed to maximize the variability of atmospheric conditions for the given time-of-day and day-of-year for each SPE event. To parameterize the inversion, we assume that the source of infrasonic energy results from the linear combination of explosion-induced surface spall and linear seismic-to-elastic mode conversion at the Earth's free surface. We find that the inversion yields relatively repeatable results for the estimated spall source whereas the estimated isotropic explosion source is highly variable. This suggests that the majority of the observed acoustic energy is produced by the spall source and/or our modeling of the elastic energy propagation, and data are subsequent conversion to acoustic energy via linear elastic-to-acoustic coupling at the surface, is too simplistic.

58 GEOSCIENCES↗
DOE OSTI2023

Main Bearing Replacement and Damage - A Field Data Study on 15 Gigawatts of Wind Energy Capacity

This study seeks to establish a comprehensive baseline of knowledge for the replacement and damage of main bearings in wind turbines. The purpose of this report is to provide a high-level summary of the data set, methodology, and results of this work. Full technical details and an extended analysis will be made available in a future publication. We collected data on main bearing replacements and reported damage from industrial partners based in Europe and the United States. In total, we obtained data for 167 wind power plants, with a combined capacity of 15.3 gigawatts (GW). Most of the data set was comprised of land-based, three-point mount, spherical roller bearings. Within this data set were 689 instances of main bearing replacement. Analysis was undertaken in two parts: first, a statistical analysis of the main bearing time-to-replacement data using survival analysis techniques; second, quantitative and qualitative analyses of the obtained damage information. Our results showed that 10% of a fixed main bearing population would be expected to have been replaced by 10.5 years. This is close to half of the 20-year design value. Fitted parametric distributions then indicated that by year 20, between 22% and 25% of main bearings are expected to have been replaced. Analysis of the damage reports revealed spalling to be the main type of damage listed. The additional presence of surface damage in the collected data indicates that at least part of the spalling cases are likely due to surface-initiated rolling contact fatigue. At this stage is not clear what proportion of spalling cases result from "wear induced", surface-initiated and subsurface-initiated rolling contact fatigue. While this work provides important insights into the current state of main bearing replacements and damage, many questions remain. An ongoing and expanding data collection and analysis effort focused on wind turbine main bearings is therefore recommended.

17 WIND ENERGY↗
NASA NTRS1973

Cyclic oxidation evaluation: Approaching application conditions

A survey is presented of the cyclic furnace and burner rig oxidation facilities at NASA-Lewis Research Center together with a review of selected test results and an initial interpretation of the data obtained. Cyclic furnace tests are used to conveniently screen alloy oxidation resistance and spall tendency; high velocity tests further indicate dynamic environmental resistance. Alloys which form scales predominantly of Cr2O3/chromite spinel spall much more than those forming alpha Al2O3/aluminate spinel scales. Weight changes due to scale spalling were used to estimate alloy depletion/thickness losses.

Barrett, C. A.↗
NASA NTRS1972

Lunar microcraters and interplanetary dust.

The ratio of spall to pit diameter of lunar microcraters decreases with decreasing crater size. The trend from micron-sized to cm-sized craters involves a transition of crater types from pit-only to pit-plus-spall craters. Some spall-only craters may have possessed a pit originally. Most microcraters are formed by the impact of primary interplanetary dust particles because melting occurred during their formation. According to experimental and theoretical data such melting phenomena require impact velocities which are consistent only with the velocity distribution of extralunar particles.

Hartung, J. B.↗
NASA NTRS1978

The role of thermal shock in cyclic oxidation

The effect of thermal shock on the spalling of oxides from the surfaces of several commercial alloys was determined. The average cooling rate was varied from approximately 240 C per second to less than 1.0 C per second during cyclic oxidation tests in air. The tests consisted of one hundred cycles of one hour at the maximum temperature (1100 or 1200 C). The alloys were HOS-875, TD-Ni, TD-NiCrAl, IN-601, IN-702, and B-1900 plus Hf. All of these alloys exhibited partial spalling within the oxide rather than total oxide loss down to bare metal. Thermal shock resulted in deformation of the metal which in turn resulted, in most cases, in changing the oxide failure mode from compressive to tensile. Tensile failures were characterized by cracking of the oxide and little loss, while compressive failures were characterized by explosive loss of platelets of oxide. This behavior was confirmed by examination of mechanically stressed oxide scales. The thermally shocked oxides spalled less than the slow cooled samples with the exception of TD-NiCrAl. This material failed in a brittle manner rather than by plastic deformation.

Lowell, C. E.↗
NASA NTRS1981

High temperature cyclic oxidation furnace testing at NASA Lewis Research Center

A standardized method of testing the cyclic oxidation resistance of various alloys in static air to 1200 C was developed and is routinely used at NASA Lewis Research Center. Test samples are automatically raised and lowered into a resistance wound furnace for a series of fixed interval heating and cooling cycles. Spall catchers collect the accumulated spall from each sample. The samples are weighed intermittently to generate specific weight change/time data. At various test times the samples and the accumulated spall are analyzed by X-ray diffraction. A computer program uses this gravimetric and X-ray data as input to print out the oxidation curves and specific weight change/time and X-ray results in a published format, organizes, and indexes the data. So far, several hundred Fe, Ni, and Co base alloys were tested using this same basic procedure and results form the basis of a series of cyclic oxidation handbooks to be published by NASA. Such specific weight change/time data were used to estimate the oxidative metal consumption by several computer modeling techniques to rank alloys and for use in life testing estimates.

Barrett, C. A.↗
NASA NTRS1981

High temperature cyclic oxidation furnace testing at NASA Lewis Research Center

A standardized method of testing the cyclic oxidation resistance of various alloys in static air up to 1200 C has been developed and routinely used at the NASA Lewis Research Center. Test samples are automatically raised and lowered into a resistance wound furnace for a series of fixed-interval heating and cooling cycles. Spall catchers collect the accumulated spall from each sample. The samples are weighed intermittently to generate specific weight change with time data. At various test times the samples and the accumulated spall are analyzed by X-ray diffraction. A computer program is used to print out the specific weight change versus time data and the X-ray data in tabular form and to plot the specific weight change versus time data in a publishable format. The data are also organized and indexed. So far several hundred Fe-, Ni-, and Co-base alloys have been tested using this basic procedure and will form the basis of a series of cyclic oxidation handbooks to be published by NASA. Such specific weight change/time data have been used to estimate the oxidative metal consumption by several computer modeling techniques both to rank alloys and to estimate life.

Barrett, C. A.↗
NASA NTRS1983

Cyclic oxidation of superalloys

The development of mathematical/computer models of cyclic oxidation in high-temperature alloys is described. The acceleration of oxidation attack caused by the spalling of protective oxide scales is discussed. The COREST paralinear model based on empirical data, designed by Barrett and Pressler, is found to be of limited value. Basic research on the spalling process in different alloy systems is reviewed, and the phenomenon is characterized: occurring mainly within the oxide, it is caused by the different thermal expansion coefficients of oxide and metal and is a linear function of the total retained oxide. This information has been used in the development of the discrete oxide-spall model COSP and in its modification by addition of a diffusion-zone-profile model to predict the failure of components (Heckel and Nesbitt, unpublished). The COSP model is shown to produce good predictions of cyclic oxidation under a variety of conditions, using data from simple isothermic tests.

Lowell, C. E.↗
NASA NTRS1989

Vacuum plasma spray coating

Currently, protective plasma spray coatings are applied to space shuttle main engine turbine blades of high-performance nickel alloys by an air plasma spray process. Originally, a ceramic coating of yttria-stabilized zirconia (ZrO2.12Y2O3) was applied for thermal protection, but was removed because of severe spalling. In vacuum plasma spray coating, plasma coatings of nickel-chromium-aluminum-yttrium (NiCrAlY) are applied in a reduced atmosphere of argon/helium. These enhanced coatings showed no spalling after 40 MSFC burner rig thermal shock cycles between 927 C (1700 F) and -253 C (-423 F), while current coatings spalled during 5 to 25 test cycles. Subsequently, a process was developed for applying a durable thermal barrier coating of ZrO2.8Y2O3 to the turbine blades of first-stage high-pressure fuel turbopumps utilizing the enhanced NiCrAlY bond-coating process. NiCrAlY bond coating is applied first, with ZrO2.8Y2O3 added sequentially in increasing amounts until a thermal barrier coating is obtained. The enchanced thermal barrier coating has successfully passed 40 burner rig thermal shock cycles.

Holmes, Richard R.↗
NASA NTRS1988

Effect of 0.1 at. pct Zirconium on the cyclic oxidation resistance of beta-NiAl

The effect of 0.1 at. pct Zr on the cyclic oxidation of hipped beta-NiAl was studied. Oxidation testing was performed in static air at 1100-1200 C, using 1-hr exposure cycles for test times up to 3000 hr. The weight change versus time data were modeled with the COSP computer program to analyze and predict cyclic-oxidation behavior. Zr additions significantly change the nature of the scale-spalling process during cooling, so that the oxide spalls near the oxide-air interface at a relatively low depth within the scale. Without Zr, the predominantly alpha-Al2O3 scale tends to spall randomly to bare metal at relatively high effective-scale-loss rates, particularly at 1150 C and 1200 C. This leads to higher rates of Al consumption for the Zr-free aluminide and much earlier depletion of Al, leading to eventual breakaway (i.e., failure).

Barrett, Charles A.↗
NASA NTRS1995

Thermal barrier coating life modeling in aircraft gas turbine engines

Analytical models useful for predicting ceramic thermal barrier coating (TBC) spalling life in aircraft gas turbine engines are presented. Electron beam-physical vapor deposited (EB-PVD) and plasma sprayed TBC systems are discussed. TBC spalling was attributed to a combination of mechanisms such as metal oxidation at the ceramic-metal interface, ceramic-metal interface stress concentrations at free surfaces due to dissimilar materials, ceramic-metal interface stresses caused by local radius of curvature and interface roughness, material properties and mechanical behavior, transient temperature gradients across the ceramic layer and component design features. TBC spalling life analytical models were developed based on observations of TBC failure modes and plausible failure theories. TBC failure was assumed to occur when the imposed stresses exceeded the material strength (at or near the ceramic-metal interface). TBC failure knowledge gaps caused by lack of experimental evidence and analytical understanding are noted. The analytical models are considered initial engineering approaches that capture observed TBC failure trends.

Nissley, D. M.↗
NASA NTRS2002

COSP for Windows: Strategies for Rapid Analyses of Cyclic Oxidation Behavior

COSP is a publicly available computer program that models the cyclic oxidation weight gain and spallation process. Inputs to the model include the selection of an oxidation growth law and a spalling geometry, plus oxide phase, growth rate, spall constant, and cycle duration parameters. Output includes weight change, the amounts of retained and spalled oxide, the total oxygen and metal consumed, and the terminal rates of weight loss and metal consumption. The present version is Windows based and can accordingly be operated conveniently while other applications remain open for importing experimental weight change data, storing model output data, or plotting model curves. Point-and-click operating features include multiple drop-down menus for input parameters, data importing, and quick, on-screen plots showing one selection of the six output parameters for up to 10 models. A run summary text lists various characteristic parameters that are helpful in describing cyclic behavior, such as the maximum weight change, the number of cycles to reach the maximum weight gain or zero weight change, the ratio of these, and the final rate of weight loss. The program includes save and print options as well as a help file. Families of model curves readily show the sensitivity to various input parameters. The cyclic behaviors of nickel aluminide (NiAl) and a complex superalloy are shown to be properly fitted by model curves. However, caution is always advised regarding the uniqueness claimed for any specific set of input parameters,

Smialek, James L.↗
NASA NTRS2003

Universal Behavior of a Cyclic Oxidation Model

A mathematical model has been generated to represent the iterative, discrete growth and spallation processes associated with cyclic oxidation. Parabolic growth kinetics (k(sub p)) over and a constant spall area (F(sub A)) were assumed, with spalling occurring interfacially at the thickest regions of the scale. Although most models require numerical techniques, the regularity and simplicity of this progression permitted an approximation by algebraic expressions. Normalization could now be performed to reflect all parametric effects, and a universal cyclic oxidation response was generated: W(sub u) = 1/2 {3J(sub u)(sup 1/2)+ J(sub u)(sup 3/2)} where W, is weight change normalized by the maximum and J(sub u) is the cycle number normalized by the number to reach maximum. Similarly, the total amount of metal consumed was represented by a single normalized curve. The factor [(S(sub c)-l)(raised dot)sqrt(F(sub A)k(sub p)DELTAt)] was identified as a general figure of merit, where S(sub c) is the mass ratio of oxide to oxygen and DELTAt is the cycle duration. A cyclic oxidation failure map was constructed, in normalized k(sub p)-F(sub A) space, as defined by the locus of points corresponding to a critical amount of metal consumption in a given time. All three constructions describe behavior for every value of growth rate, spall fraction, and cycle duration by means of single curves, but with two branches corresponding to the times before and after steady state is achieved.

Smialek, James L.↗
NASA NTRS2002

Cyclic Oxidation Modeling Program Rewritten for MS Windows

Turbine superalloy components are subject to high-temperature oxidation during operation. Protection is often conferred by coatings designed to form slow-growing, adherent oxide scales. Degradation by oxidation is exacerbated by the thermal cycling encountered during normal aircraft operations. Cooling has been identified as the major contributor to stresses in the oxidation scales, and it may often cause some oxide scale spallation with a proportional loss of protective behavior. Overall oxidation resistance is, thus, studied by the weight change behavior of alloy coupons during high-temperature cyclic oxidation in furnace or burner rig tests. The various characteristics of this behavior are crucial in understanding the performance of alloys at high temperatures. This new modeling effort helps in the understanding of the major factors involved in the cyclic oxidation process. Weight change behavior in cyclic oxidation is typified by an initial parabolic weight gain response curve that eventually exhibits a maximum, then transitions into a linear rate of weight loss due to spalling. The overall shape and magnitude of the curve are determined by the parabolic growth rate, kp, the cycle duration, the type of oxide scale, and the regular, repetitive spalling process. This entire process was modeled by a computer program called the Cyclic Oxidation Spalling Program (COSP) previously developed at the NASA Glenn Research Center. Thus, by supplying appropriate oxidation input parameters, one can determine the best fit to the actual data. These parameters describe real behavior and can be used to compare alloys and project cyclic oxidation behavior for longer times or under different cycle frequencies.

Smialek, James L.↗
NASA NTRS2009

Cratering Equations for Zinc Orthotitanate Coated Aluminum

The final STS-125 servicing mission (SM4) to the Hubble Space Telescope (HST) in May of 2009 saw the return of the 2nd Wide Field Planetary Camera (WFPC2) aboard the shuttle Discovery. This hardware had been in service on HST since it was installed during the SM1 mission in December of 1993 yielding one of the longest low Earth orbit exposure times (15.4 years) of any returned space hardware. The WFPC2 is equipped with a 0.8 x 2.2 m radiator for thermal control of the camera electronics (Figure 1). The space facing surface of the 4.1 mm thick aluminum radiator is coated with Z93 zinc orthotitanate thermal control paint with a nominal thickness of 0.1 0.2 mm. Post flight inspections of the radiator panel revealed hundreds of micrometeoroid/orbital debris (MMOD) impact craters ranging in size from less than 300 to nearly 1000 microns in diameter. The Z93 paint exhibited large spall areas around the larger impact sites (Figure 2) and the craters observed in the 6061-T651 aluminum had a different shape than those observed in uncoated aluminum. Typical hypervelocity impact craters in aluminum have raised lips around the impact site. The craters in the HST radiator panel had suppressed crater lips, and in some cases multiple craters were present instead of a single individual crater. Humes and Kinard observed similar behavior after the WFPC1 post flight inspection and assumed the Z93 coating was acting like a bumper in a Whipple shield. Similar paint behavior (spall) was also observed by Bland2 during post flight inspection of the International Space Station (ISS) S-Band Antenna Structural Assembly (SASA) in 2008. The SASA, with similar Z93 coated aluminum, was inspected after nearly 4 years of exposure on the ISS. The multi-crater phenomena could be a function of the density, composition, or impact obliquity angle of the impacting particle. For instance, a micrometeoroid particle consisting of loosely bound grains of material could be responsible for creating the multiple craters. Samples were obtained from the HST largest craters for examination by electron microscope equipped with x-ray spectrometers to determine impactor source (micrometeoroid or orbital debris). In an attempt to estimate the MMOD particle diameters that produced these craters, this paper will present equations for spall diameter, crater depth and crater diameter in Z93 coated aluminum. The equations will be based on hypervelocity impact tests of Z93 painted aluminum at the NASA White Sands Test Facility. Equations inputs for velocities beyond the testable regime are expected from hydrocode simulations of Z93 coated aluminum using CTH and ANSYS AUTODYN.

Hyde, James↗