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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS1956

Interim Report on Fatigue Characteristics of a Typical Metal Wing

Constant amplitude fatigue tests of seventy-two P-51D "Mustang" wings are reported. The tests were performed by a vibrational loading system and by an hydraulic loading device for conditions with and without varying amounts of pre-load. The results indicate that: (a) the frequency of occurrence of fatigue at any one location is related to the range of the loads applied, (b) the rate of propagation of visible cracks is more or less constant for a large portion of the life of the specimen, (c) the fatigue strength of the structure is similar to that of notched material having a theoretical stress concentration factor of more than 3.0, (d) the frequency distribution of fatigue life is approximately logarithmic normal, (e) the relative increase in fatigue life for a given pre-load depends on the maximum load of the loading cycle only, while the optimum pre-load value is approximately 85 percent of the ultimate failing load, and (f) that normal design procedure will not permit the determination of local stress levels with sufficient accuracy to determine the fatigue strength of an element of a redundant structure.

LOADS AND STRESSES, STRUCTURAL - REPEATED DYNAMIC↗
NASA NTRS2021

Residual Stresses Induced due to Curing of the Bulk Matrix in a Simplified Three-Dimensional (3D) Woven Repeating Unit Cell

It has been observed that 3D woven materials are highly susceptible to processes induced defects including tow misalignment, intratow and intertow cracking and/or voids. Adequate process modeling of 3D woven Polymer Matrix Composites (PMCs) is necessary to predict and estimate the effects of the manufacturing process on these defects. A preliminary step towards this is achieved with the commercial Finite Element Analysis (FEA) tool Abaqus complemented with written user subroutines to account for the effect of shrinkage and thermoelastic properties evolution as a function of the degree of cure of the bulk matrix phase in a 3D woven composite repeating unit cell (RUC). As a pathfinder, the process modeling framework is demonstrated on a simplified 3D woven RUC of an AS4/RIMR 135 system. Curing simulations are performed on the 3D woven RUC to observe the processing induced residual stresses. The results of the analysis show that high stress concentrations, present within the 3D intertow matrix bordering the binder tow, coincide with X-Ray computed tomography (X-Ray-CT) scan data depicting cracking in the same location

3D Woven↗
NASA NTRS2007

Structural Analysis of the Redesigned Ice/Frost Ramp Bracket

This paper describes the interim structural analysis of a redesigned Ice/Frost Ramp bracket for the Space Shuttle External Tank (ET). The proposed redesigned bracket consists of mounts for attachment to the ET wall, supports for the electronic/instrument cables and propellant repressurization lines that run along the ET, an upper plate, a lower plate, and complex bolted connections. The eight nominal bolted connections are considered critical in the summarized structural analysis. Each bolted connection contains a bolt, a nut, four washers, and a non-metallic spacer and block that are designed for thermal insulation. A three-dimensional (3D) finite element model of the bracket is developed using solid 10-node tetrahedral elements. The loading provided by the ET Project is used in the analysis. Because of the complexities associated with accurately modeling the bolted connections in the bracket, the analysis is performed using a global/local analysis procedure. The finite element analysis of the bracket identifies one of the eight bolted connections as having high stress concentrations. A local area of the bracket surrounding this bolted connection is extracted from the global model and used as a local model. Within the local model, the various components of the bolted connection are refined, and contact is introduced along the appropriate interfaces determined by the analysts. The deformations from the global model are applied as boundary conditions to the local model. The results from the global/local analysis show that while the stresses in the bolts are well within yield, the spacers fail due to compression. The primary objective of the interim structural analysis is to show concept viability for static thermal testing. The proposed design concept would undergo continued design optimization to address the identified analytical assumptions and concept shortcomings, assuming successful thermal testing.

Phillips, D. R.↗
NASA NTRS1983

Notch strength of composites

The notch strength of composites is discussed. The point stress and average stress criteria relate the notched strength of a laminate to the average strength of a relatively long tensile coupon. Tests of notched specimens in which microstrain gages have been placed at or near the edges of the holes have measured strains much larger that those measured in an unnotched tensile coupon. Orthotropic stress concentration analyses of failed notched laminates have also indicated that failure occurred at strains much larger than those experienced on tensile coupons with normal gage lengths. This suggests that the high strains at the edge of a hole can be related to the very short length of fiber subjected to these strains. Lockheed has attempted to correlate a series of tests of several laminates with holes ranging from 0.19 to 0.50 in. Although the average stress criterion correlated well with test results for hole sizes equal to or greater than 0.50 in., it over-estimated the laminate strength in the range of hole sizes from 0.19 to 0.38 in. It thus appears that a theory is needed that is based on the mechanics of failure and is more generally applicable to the range of hole sizes and the varieties of laminates found in aircraft construction.

Whitney, J. M.↗
NASA NTRS1993

Physical properties of glasses exposed to Earth-facing and trailing-side environments on LDEF

The exposure of 108 glass samples and 12 glass-ceramic samples to Earth-orbit environments permitted measurements which establish the effects of each environment. Examination of five glass types and one glass ceramic located on both the Earth-facing side and the trailing edge revealed no reduction in strength within experimental limits. Strength measurements subjected less than 5 percent of the sample surface area to stresses above 90 percent of the glass's failure strength. Seven micrometeorite or space debris impacts occurred on trailing edge samples. One of those impacts occurred in a location which was subjected to 50 percent of the applied stress at failure. Micrometeorite or space debris impacts were not observed on Earth-facing samples. The physical shape and structure of the impact sites were carefully examined using stereographic scanning electron microscopy. These impacts induce a stress concentration at the damaged region which influences mechanical strength. The flaw size produced by such damage was examined to determine the magnitude of strength degradation in micrometeorite or space-debris impacted glasses. Scanning electron microscopy revealed topographical details of impact sites which included central melt zones and glass fiber production. The overall crater structure is similar to much larger impacts of large meteorite on the Moon in that the melt crater is surrounded by shocked regions of material which fracture zones and spall areas. Residual stresses arising from shock compression and cooling of the fused zone cannot currently be included in fracture mechanics analyses based on simple flaw size examination.

Wiedlocher, David E.↗
NASA NTRS2024

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

The utilization of lattice-type cellular architectures has seen a significant increase, owing to their predictable shape and the ability to fabricate templated porous materials through low-cost 3D-printing methods. Frames based on atomic lattice structures such as face-centered cubic (FCC), body-centered cubic (BCC), or simple cubic (SC) have been utilized. In FDM, the mechanical performance has been impeded by stress concentration at the nodes and melt-solidification interfaces arising from layer-by-layer deposition. Adding plates to the frames has resulted in improvements with a concurrent increase in weight and hot-pocket-induced dimensional impact in the closed cells formed. In this paper, we explore compressive performance from the partial addition of plates to the frames of a SC-BCC lattice. Compression testing of both single unit cells and 4 × 4 × 4 lattices in all three axial directions is conducted to examine stress transfer to the nearest neighbor and assess scale-up stress transfer. Our findings reveal that hybrid lattice structure unit cells exhibit significantly improved modulus in the range of 125% to 393%, specific modulus in the range of 13% to 120%, and energy absorption in the range of 17% to 395% over the open lattice. The scaled-up lattice modulus increased by 8% to 400%, specific modulus by 2% to 107%, and energy absorption by 37% to 553% over the lattice frame. Parameters that emerged as key to improved lightweighting.

FDM↗
NASA NTRS1981

Force instrumentation for cryogenic wind tunnels using one-piece strain-gage balances

Materials and techniques for a transducer capable of obtaining accurate force measurements at cryogenic temperatures (down to 77 K) and high pressures (up to 9 atm) have been determined. Areas of high stress concentration are minimized by balance design, and model and sting attachment methods able to withstand cryogenic temperatures are used. Maraging 200 is the material used for the balances, due to its high impact strength and simple heat treatment procedure. Test results verify that the balances produce reliable, repeatable, and predictable data from 300 K to 110 K under steady state conditions. Techniques have been developed to reduce the temperature-induced bridge output, such as the use of bridges with two gages mounted transverse to the principal stress direction. Under these conditions, the results given by the balances should be equally good during transient temperatures on five of the six components. The work will be used at the National Transonic Facility (NTF) at NASA Langley.

Ferris, A. T.↗
NASA NTRS2004

The Effect of Hole Quality on the Fatigue Life of 2024-T3 Aluminum Alloy Sheet

This paper presents the results of a study whose main objective was to determine which type of fabrication process would least affect the fatigue life of an open-hole structural detail. Since the open-hole detail is often the fundamental building block for determining the stress concentration of built-up structural parts, it is important to understand any factor that can affect the fatigue life of an open hole. A test program of constant-amplitude fatigue tests was conducted on five different sets of test specimens each made using a different hole fabrication process. Three of the sets used different mechanical drilling procedures while a fourth and fifth set were mechanically drilled and then chemically polished. Two sets of specimens were also tested under spectrum loading to aid in understanding the effects of residual compressive stresses on fatigue life. Three conclusions were made from this study. One, the residual compressive stresses caused by the hole-drilling process increased the fatigue life by two to three times over specimens that were chemically polished after the holes were drilled. Second, the chemical polishing process does not appear to adversely affect the fatigue life. Third, the chemical polishing process will produce a stress-state adjacent to the hole that has insignificant machining residual stresses.

Everett, Richard A., Jr.↗
NASA NTRS1993

Tension fracture of laminates for transport fuselage. Part 2: Large notches

Tests were conducted on over 200 center-crack specimens to evaluate: (a) the tension-fracture performance of candidate materials and laminates for commercial fuselage applications; and (b) the accuracy of several failure criteria in predicting response. Crack lengths of up to 12 inches were considered. Other variables included fiber/matrix combination, layup, lamination manufacturing process, and intraply hybridization. Laminates fabricated using the automated tow-placement process provided significantly higher tension-fracture strengths than nominally identical tape laminates. This confirmed earlier findings for other layups, and possibly relates to a reduced stress concentration resulting from a larger scale of repeatable material inhomogeneity in the tow-placed laminates. Changes in material and layup result in a trade-off between small-notch and large-notch strengths. Toughened resins and 0 deg-dominate layups result in higher small-notch strengths but lower large-notch strengths than brittle resins, 90 deg and 45 deg dominated layups, and intraply S2-glass hybrid material forms. Test results indicate that strength-prediction methods that allow for a reduced order singularity of the crack-tip stress field are more successful at predicting failure over a range of notch sizes than those relying on the classical square-root singularity. The order of singularity required to accurately predict large-notch strength from small-notch data was affected by both material and layup. Measured crack-tip strain distributions were generally higher than those predicted using classical methods. Traditional methods of correcting for finite specimen width were found to be lacking, confirming earlier findings with other specimen geometries. Fracture tests of two stiffened panels, identical except for differing materials, with severed central stiffeners resulted in nearly identical damage progression and failure sequences. Strain-softening laws implemented within finite element models appear attractive to account for load redistribution in configured structure due to damage-induced crack tip softening

Walker, Tom H.↗
NASA NTRSDate not supplied

Novel Test and Analysis Methodology for the Assessment of Joint under Re-entry Environment

Spacecraft thermal protection systems require unique approaches for design verification due to the extreme environments seen during space travel and atmospheric re-entry. In this work, unique considerations for design, analysis, and verification of a tiled heatshield design with material nonlinearity, material property temperature-dependency, material property rate-dependency, and geometric stress concentrations are presented. Such designs require a thorough application of the building block approach to derive appropriate material property datasets, and a novel application of analysis models to aid in the structural verification with testing. The custom application of material rate-dependency in finite element analysis software is presented as a means of leveraging the rate-dependent test data for the material property dataset. Because bonded tile heatshields contain so many design considerations and nonlinearities which often preclude the ability to easily achieve the requisite test factors in qualification testing, a novel sub-element test was developed that amplifies the stress singularity beyond flight conditions. The test achieves an over-test over flight stress conditions. The approach for sub-element coupon design can be extended to other bonded joint designs and can be used in aiding a qualification program.

Pavel Babuska↗
NASA NTRS1989

Comparison of boundary element and finite element methods in spur gear root stress analysis

The boundary element method (BEM) is used to compute fillet stress concentration in spur gear teeth. The results are shown to compare favorably with analogous results obtained using the finite element method (FEM). A partially supported thin rim gear is studied. The loading is applied at the pitch point. A three-dimensional analysis is conducted using both the BEM and FEM (NASTRAN). The results are also compared with those of a two-dimensional finite element model. An advantage of the BEM over the FEM is that fewer elements are needed with the BEM. Indeed, in the current study the BEM used 92 elements and 270 nodes whereas the FEM used 320 elements and 2037 nodes. Moreover, since the BEM is especially useful in problems with high stress gradients it is potentially a very useful tool for fillet stress analyses.

Sun, H.↗
NASA NTRS2011

Scoring Dawg Core Breakoff and Retention Mechanism

This novel core break-off and retention mechanism consists of a scoring dawg controlled by a set of two tubes (a drill tube and an inner tube). The drill tube and the inner tube have longitudinal concentric holes. The solution can be implemented in an eccentric tube configuration as well where the tubes have eccentric longitudinal holes. The inner tube presents at the bottom two control surfaces for controlling the orientation of the scoring dawg. The drill tube presents a sunk-in profile on the inside of the wall for housing the scoring dawg. The inner tube rotation relative to the drill tube actively controls the orientation of the scoring dawg and hence its penetration and retrieval from the core. The scoring dawg presents a shaft, two axially spaced arms, and a tooth. The two arms slide on the control surfaces of the inner tube. The tooth, when rotated, can penetrate or be extracted from the core. During drilling, the two tubes move together maintaining the scoring dawg completely outside the core. After the desired drilling depth has been reached the inner tube is rotated relative to the drill tube such that the tooth of the scoring dawg moves toward the central axis. By rotating the drill tube, the scoring dawg can score the core and so reduce its cross sectional area. The scoring dawg can also act as a stress concentrator for breaking the core in torsion or tension. After breaking the core, the scoring dawg can act as a core retention mechanism. For scoring, it requires the core to be attached to the rock. If the core is broken, the dawg can be used as a retention mechanism. The scoring dawg requires a hard-tip insert like tungsten carbide for scoring hard rocks. The relative rotation of the two tubes can be controlled manually or by an additional actuator. In the implemented design solution the bit rotation for scoring was in the same direction as the drilling. The device was tested for limestone cores and basalt cores. The torque required for breaking the 10-mm diameter limestone cores was 5 to 5.8 lb-in. (0.56 to 0.66 N-m).

Badescu, Mircea↗
NASA NTRS2006

Studies of acoustic-electric feed-throughs for power transmission through structures

There are numerous engineering design problems where the use of wires to transfer power and communicate data thru the walls of a structure is prohibitive or significantly difficult that it may require a complex design. Using physical feedthroughs in such systems may make them susceptible to leakage of chemicals or gasses, loss of pressure or vacuum, as well as difficulties in providing adequate thermal or electrical insulation. Moreover, feeding wires thru a wall of a structure reduces the strength of the structure and makes the structure prone to cracking due to fatigue that can result from cyclic loading and stress concentrations. One area that has already been identified to require a wireless alternative to electrical feedthroughs is the container of the Mars Sample Return Mission, which will need wireless sensors to sense a pressure leak and to avoid potential contamination. The idea of using elastic or acoustic waves to transfer power was suggested recently by [Y. Hu, et al., July 2003]. This system allows for the avoidance of cabling or wiring. The technology is applicable to the transfer of power for actuation, sensing and other tasks inside any sealed container or vacuum/pressure vessel. An alternative approach to the modeling presented previously [Sherrit et a., 2005] used network analysis to solve the same problem in a clear and expandable manner. Experimental tests on three different designs of these devices were performed. The three designs used different methods of coupling the piezoelectric element to the wall. In the first test the piezoelectric material was bolted using a backing structure. In the second test the piezoelectric was clamped after the application of grease and finally the piezoelectric element was attached using a conductive epoxy. The mechanical clamp with grease produced the highest measured efficiency of 53% however this design was the least practical from a fabrication viewpoint. The power transfer efficiency of conductive epoxy joint was 40% and the stress bolts (12%).

ultrasonics↗
NASA NTRS1967

Analysis of stability-critical orthotropic cylinders subjected to axial compression

Analytical procedure for determining critical buckling loads of orthotropic cylinders subjected to axial compression loading has been defined. Three modes of instability have been considered - general instability, local instability caused by panel and interframe buckling, and local instability caused by yielding and crippling in areas of stress concentration.

Finley, R. L.↗