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At least 217 records · Page 12

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NASA NTRS1991

Dynamic delamination crack propagation in a graphite/epoxy laminate

Dynamic delamination crack propagation in a (90/0) 5s Graphite/Epoxy laminate with an embedded interfacial crack was investigated experimentally using high speed photography. The dynamic motion was produced by impacting the beamlike laminate specimen with a silicon rubber ball. The threshold impact velocities required to initiate dynamic crack propagation in laminates with varying initial crack positions were determined. The crack propagation speeds were estimated from the photographs. Results show that the through the thickness position of the embedded crack can significantly affect the dominant mechanism and the threshold impact velocity for the onset of crack movement. If the initial delamination is placed near the top of bottom surface of the laminate, local buckling of the delaminated plies may cause instability of the crack. If the initial delamination lies on the midplane, local buckling does not occur and the initiation of crack propagation appears to be dominated by Mode II fracture. The crack propagation and arrest observed was seen to be affected by wave motion within the delamination region.

Grady, J. E.↗

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 NTRS1992

Modeling of crack bridging in a unidirectional metal matrix composite

The effective fatigue crack driving force and crack opening profiles were determined analytically for fatigue tested unidirectional composite specimens exhibiting fiber bridging. The crack closure pressure due to bridging was modeled using two approaches: the fiber pressure model and the shear lag model. For both closure models, the Bueckner weight function method and the finite element method were used to calculate crack opening displacements and the crack driving force. The predicted near crack tip opening profile agreed well with the experimentally measured profiles for single edge notch SCS-6/Ti-15-3 metal matrix composite specimens. The numerically determined effective crack driving force, Delta K(eff), was calculated using both models to correlate the measure crack growth rate in the composite. The calculated Delta K(eff) from both models accounted for the crack bridging by showing a good agreement between the measured fatigue crack growth rates of the bridged composite and that of unreinforced, unbridged titanium matrix alloy specimens.

Ghosn, Louis J.↗

NASA NTRS1990

Subcritical crack growth in soda-lime glass in combined mode I and mode II loading

Subcritical crack growth under mixed-mode loading was studied in soda-lime glass. Pure mode I, combined mode I and mode II, and pure mode II loadings were achieved in precracked disk specimens by loading in diametral compression at selected angles with respect to the symmetric radial crack. Crack growth was monitored by measuring the resistance changes in a microcircuit grid consisting of parallel, electrically conducting grid lines deposited on the surface of the disk specimens by photolithography. Subcritical crack growth rates in pure mode I, pure mode II, and combined mode I and mode II loading could be described by an exponential relationship between crack growth rate and an effective crack driving force derived from a mode I-mode II fracture toughness envelope. The effective crack driving force was based on an empirical representation of the noncoplanar strain energy release rate. Stress intensities for kinked cracks were assessed using the method of caustics and an initial decrease and a subsequent increase in the subcritical crack growth rates of kinked cracks were shown to correlate with the variations of the mode I and the mode II stress intensities.

Singh, Dileep↗

NASA NTRS1993

A fracture criterion for widespread cracking in thin-sheet aluminum alloys

An elastic-plastic finite-element analysis was used with a critical crack-tip-opening angle (CTOA) fracture criterion to model stable crack growth in thin-sheet 2024-T3 aluminum alloy panels with single and multiple-site damage (MSD) cracks. Comparisons were made between critical angles determined from the analyses and those measured with photographic methods. Calculated load against crack extension and load against crack-tip displacement on single crack specimens agreed well with test data even for large-scale plastic deformations. The analyses were also able to predict the stable tearing behavior of large lead cracks in the presence of stably tearing MSD cracks. Small MSD cracks significantly reduced the residual strength for large lead cracks.

Newman, J. C., Jr.↗

NASA NTRS1994

Stability and stability degree of a cracked flexible rotor supported on journal bearings

This paper investigates the stability and the stability degree of a flexible cracked rotor supported on different kinds of journal bearings. It is found that no matter what kind of bearings is used, the unstable zones caused by rotor crack locate always within the speed ratio (2/N) (1 - Delta K(sub xi)/4) is less than Omega is less than 2/N when gravity parameter W(sub R) is greater than 1.0, and locate always within the speed ratio (2 Omega(sub alpha)/N) (1 - Delta K(sub xi)/4) is less than Omega is less than 2 Omega(sub alpha)/N when W(sub R) is less than 0.1, where Delta K(sub xi) is the crack stiffness ratio, N = 1, 2, 3, 4, 5, ..., and Omega(sub alpha) = ((1 + 2 alpha)/2 alpha)(exp 1/2). When 0.1 is less than W(sub R) is less than 1.0, there is a region where no unstable zones caused by rotor crack exist. Outside the crack ridge zones, the rotor crack has almost no influence on system's stability and stability degree; while within the crack ridge zones, the stability and stability degree depend both on the crack and system's parameters. In some cases, the system may still be stable even when the crack is very large. For small gravity parameter (W(sub R) is less than 0.1), the mass ratio alpha has large influence on the position of unstable region, but its influence on the stability degree is small. The influence of fixed Sommerfeld number S(sub 0) on the crack stability degree is small although S(sub 0) has large influence on the stability degree of uncracked rotor.

Meng, Guang↗

NASA NTRS1994

Variations of a global constraint factor in cracked bodies under tension and bending loads

Elastic-plastic finite-element analyses were used to calculate stresses and displacements around a crack in finite-thickness plates for an elastic-perfectly plastic material. Middle- and edge-crack specimens were analyzed under tension and bending loads. Specimens were 1.25 to 20 mm thick with various widths and crack lengths. A global constraint factor alpha(sub g), an averaged normal-stress to flow-stress ratio over the plastic region, was defined to simulate three-dimensional (3D) effects in two-dimensional (2D) models. For crack lengths and uncracked ligament lengths greater than four times the thickness, the global constraint factor was found to be nearly a unique function of a normalized stress-intensity factor (related to plastic-zone size to thickness ratio) from small- to large-scale yielding conditions for various specimen types and thickness. For crack length-to-thickness ratios less than four, the global constraint factor was specimen type, crack length and thickness dependent. Using a 2D strip-yield model and the global constraint factors, plastic-zone sizes and crack-tip displacements agreed reasonably well with the 3D analyses. For a thin sheet aluminum alloy, the critical crack-tip-opening angle during stable tearing was found to be independent of specimen type and crack length for crack length-to-thickness ratios greater than 4.

Newman, J. C., Jr.↗

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 NTRS1995

Separation of crack extension modes in orthotropic delamination models

In the analysis of an interface crack between dissimilar elastic materials, the mode of crack extension is typically not unique, due to oscillatory behavior of near-tip stresses and displacements. This behavior currently limits the applicability of interfacial fracture mechanics as a means to predict composite delamination. The Virtual Crack Closure Technique (VCCT) is a method used to extract mode 1 and mode 2 energy release rates from numerical fracture solutions. The mode of crack extension extracted from an oscillatory solution using the VCCT is not unique due to the dependence of mode on the virtual crack extension length, Delta. In this work, a method is presented for using the VCCT to extract Delta-independent crack extension modes for the case of an interface crack between two in-plane orthotropic materials. The method does not involve altering the analysis to eliminate its oscillatory behavior. Instead, it is argued that physically reasonable, Delta-independent modes of crack extension can be extracted from oscillatory solutions. Knowledge of near-tip fields is used to determine the explicit Delta dependence of energy release rate parameters. Energy release rates are then defined that are separated from the oscillatory dependence on Delta. A modified VCCT using these energy release rate definitions is applied to results from finite element analyses, showing that Delta-independent modes of crack extension result. The modified technique has potential as a consistent method for extracting crack extension modes from numerical solutions. The Delta-independent modes extracted using this technique can also serve as guides for testing the convergence of finite element models. Direct applications of this work include the analysis of planar composite delamination problems, where plies or debonded laminates are modeled as in-plane orthotropic materials.

Beuth, Jack L.↗

NASA NTRS1999

Crack Growth Simulation and Residual Strength Prediction in Airplane Fuselages

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

Chen, Chuin-Shan↗

NASA NTRS2001

The Effects of Shot and Laser Peening on Fatigue Life and Crack Growth in 2024 Aluminum Alloy and 4340 Steel

Fatigue and crack growth tests have been conducted on 4340 steel and 2024-T3 aluminum alloy, respectively, to assess the effects of shot peening on fatigue life and the effects of shot and laser peening on crack growth. Two current programs involving fixed and rotary-wing aircraft will not be using shot peened structures. Since the shot peening compressive residual stress depth is usually less than the 0.05-inch initial damage tolerance crack size, it is believed by some that shot peening should have no beneficial effects toward retarding crack growth. In this study cracks were initiated from an electronic-discharged machining flaw which was cycled to produce a fatigue crack of approximately 0.05-inches in length and then the specimens were peened. Test results showed that after peening the crack growth rates were noticeably slower when the cracks were fairly short for both the shot and laser peened specimens resulting in a crack growth life that was a factor of 2 to 4 times greater than the results of the average unpeened test. Once the cracks reached a length of approximately 0.1-inches the growth rates were about the same for the peened and unpeened specimens. Fatigue tests on 4340 steel showed that the endurance limit of a test specimen with a 0.002-inch-deep machining-like scratch was reduced by approximately 40 percent. However, if the "scratched" specimen was shot peened after inserting the scratch, the fatigue life returned to almost 100 percent of the unflawed specimens original fatigue life.

Everett, R. A., Jr.↗

NASA NTRS2002

Generating Fatigue Crack Growth Thresholds with Constant Amplitude Loads

The fatigue crack growth threshold, defining crack growth as either very slow or nonexistent, has been traditionally determined with standardized load reduction methodologies. Some experimental procedures tend to induce load history effects that result in remote crack closure from plasticity. This history can affect the crack driving force, i.e. during the unloading process the crack will close first at some point along the wake, reducing the effective load at the crack tip. One way to reduce the effects of load history is to propagate a crack under constant amplitude loading. As a crack propagates under constant amplitude loading, the stress intensity factor, K, will increase, as will the crack growth rate, da/dN. A fatigue crack growth threshold test procedure is developed and experimentally validated that does not produce load history effects and can be conducted at a specified stress ratio, R.

Forth, Scott C.↗

NASA NTRS2001

The Growth of Small Corrosion Fatigue Cracks in Alloy 7075

The corrosion fatigue crack growth characteristics of small (less than 35 microns) surface and corner cracks in aluminum alloy 7075 is established. The early stage of crack growth is studied by performing in situ long focal length microscope (500X) crack length measurements in laboratory air and 1% NaCl environments. To quantify the "small crack effect" in the corrosive environment, the corrosion fatigue crack propagation behavior of small cracks is compared to long through-the-thickness cracks grown under identical experimental conditions. In salt water, long crack constant K(sub max) growth rates are similar to small crack da/dN.

Piascik, R. S.↗

NASA NTRS2004

Distribution of Inclusion-Initiated Fatigue Cracking in Powder Metallurgy Udimet 720 Characterized

In the absence of extrinsic surface damage, the fatigue life of metals is often dictated by the distribution of intrinsic defects. In powder metallurgy (PM) alloys, relatively large defects occur rarely enough that a typical characterization with a limited number of small volume fatigue test specimens will not adequately sample inclusion-initiated damage. Counterintuitively, inclusion-initiated failure has a greater impact on the distribution in PM alloy fatigue lives because they tend to have fewer defects than their cast and wrought counterparts. Although the relative paucity of defects in PM alloys leads to higher mean fatigue lives, the distribution in observed lives tends to be broader. In order to study this important failure initiation mechanism without expending an inordinate number of specimens, a study was undertaken at the NASA Glenn Research Center where known populations of artificial inclusions (seeds) were introduced to production powder. Fatigue specimens were machined from forgings produced from the seeded powder. Considerable effort has been expended in characterizing the crack growth rate from inclusion-initiated cracks in seeded PM alloys. A rotating and translating positioning system, with associated software, was devised to map the surface inclusions in low-cycle fatigue (LCF) test bars and to monitor the crack growth from these inclusions. The preceding graph illustrates the measured extension in fatigue cracks from inclusions on a seeded LCF test bar subjected to cyclic loading at a strain range of 0.8 percent and a strain ratio (max/min) of zero. Notice that the observed inclusions fall into three categories: some do not propagate at all (arrest), some propagate with a decreasing crack growth rate, and a few propagate at increasing rates that can be modeled by fracture mechanics. The following graph shows the measured inclusion-initiated crack growth rates from 10 interrupted LCF tests plotted against stress intensities calculated for semi-elliptical cracks with the observed surface lengths. The expected scatter in the crack growth rates for stress intensity ranges near threshold is observed. These data will be used to help determine the distribution in growth rates of cracks emanating from inclusions as well as the proportion of cracks that arrest under various loading conditions.

Bonacuse, Peter J.↗

NASA NTRS2005

Reaction Control System Thruster Cracking Consultation: NASA Engineering and Safety Center (NESC) Materials Super Problem Resolution Team (SPRT) Findings

The shuttle orbiter s reaction control system (RCS) primary thruster serial number 120 was found to contain cracks in the counter bores and relief radius after a chamber repair and rejuvenation was performed in April 2004. Relief radius cracking had been observed in the 1970s and 1980s in seven thrusters prior to flight; however, counter bore cracking had never been seen previously in RCS thrusters. Members of the Materials Super Problem Resolution Team (SPRT) of the NASA Engineering and Safety Center (NESC) conducted a detailed review of the relevant literature and of the documentation from the previous RCS thruster failure analyses. It was concluded that the previous failure analyses lacked sufficient documentation to support the conclusions that stress corrosion cracking or hot-salt cracking was the root cause of the thruster cracking and lacked reliable inspection controls to prevent cracked thrusters from entering the fleet. The NESC team identified and performed new materials characterization and mechanical tests. It was determined that the thruster intergranular cracking was due to hydrogen embrittlement and that the cracking was produced during manufacturing as a result of processing the thrusters with fluoride-containing acids. Testing and characterization demonstrated that appreciable environmental crack propagation does not occur after manufacturing.

MacKay, Rebecca A.↗

NASA NTRS2012

Modeling Transverse Cracking in Laminates With a Single Layer of Elements Per Ply

The objective of the present paper is to investigate the ability of mesolevel X-FEM models with a single layer of elements per ply to capture accurately all aspects of matrix cracking. In particular, we examine whether the model can predict the insitu ply thickness effect on crack initiation and propagation, the crack density as a function of strain, the strain for crack saturation, and the interaction between delamination and transverse cracks. Results reveal that the simplified model does not capture correctly the shear-lag relaxation of the stress field on either side of a crack, which leads to an overprediction of the crack density. It is also shown, however, that after onset of delamination many of the inserted matrix cracks close again, and that the density of open cracks becomes similar to the density predicted by the detailed model. The degree to which the spurious cracks affect the global response is quantified and the reliability of the mesolevel approach with a single layer of elements per ply is discussed.

Van Der Meer, Frans P.↗

NASA NTRS2013

Three Dimensional Numerical Simulation and Characterization of Crack Growth in the Weld Region of a Friction Stir Welded Structure

Friction stir welding (FSW) fabrication technology is being adopted in aerospace applications. The use of this technology can reduce production cost, lead-times, reduce structural weight and need for fasteners and lap joints, which are typically the primary locations of crack initiation and multi-site fatigue damage in aerospace structures. FSW is a solid state welding process that is well-suited for joining aluminum alloy components; however, the process introduces residual stresses (both tensile and compressive) in joined components. The propagation of fatigue cracks in a residual stress field and the resulting redistribution of the residual stress field and its effect on crack closure have to be estimated. To insure the safe insertion of complex integral structures, an accurate understanding of the fatigue crack growth behavior and the complex crack path process must be understood. A life prediction methodology for fatigue crack growth through the weld under the influence of residual stresses in aluminum alloy structures fabricated using FSW will be detailed. The effects and significance of the magnitude of residual stress at a crack tip on the estimated crack tip driving force are highlighted. The location of the crack tip relative to the FSW and the effect of microstructure on fatigue crack growth are considered. A damage tolerant life prediction methodology accounting for microstructural variation in the weld zone and residual stress field will lead to the design of lighter and more reliable aerospace structures

Seshadri, Banavara R.↗

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.↗