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NASA NTRS2005

Fatigue Behavior and Deformation Mechanisms in Inconel 718 Superalloy Investigated

The nickel-base superalloy Inconel 718 (IN 718) is used as a structural material for a variety of components in the space shuttle main engine (SSME) and accounts for more than half of the total weight of this engine. IN 718 is the bill-of-material for the pressure vessels of nickel-hydrogen batteries for the space station. In the case of the space shuttle main engine, structural components are typically subjected to startup and shutdown load transients and occasional overloads in addition to high-frequency vibratory loads from routine operation. The nickel-hydrogen battery cells are prooftested before service and are subjected to fluctuating pressure loads during operation. In both of these applications, the structural material is subjected to a monotonic load initially, which is subsequently followed by fatigue. To assess the life of these structural components, it is necessary to determine the influence of a prior monotonic load on the subsequent fatigue life of the superalloy. An insight into the underlying deformation and damage mechanisms is also required to properly account for the interaction between the prior monotonic load and the subsequent fatigue loading. An experimental investigation was conducted to establish the effect of prior monotonic straining on the subsequent fatigue behavior of wrought, double-aged, IN 718 at room temperature. First, monotonic strain tests and fully-reversed, strain-controlled fatigue tests were conducted on uniform-gage-section IN 718 specimens. Next, fully reversed fatigue tests were conducted under strain control on specimens that were monotonically strained in tension. Results from this investigation indicated that prior monotonic straining reduced the fatigue resistance of the superalloy particularly at the lowest strain range. Some of the tested specimens were sectioned and examined by transmission electron microscopy to reveal typical microstructures as well as the active deformation and damage mechanisms under each of the loading conditions. In monotonically strained specimens, deformation during the subsequent fatigue loading was mainly confined to the deformation bands initiated during the prior monotonic straining. This can cause dislocations to move more readily along the previously activated deformation bands and to pile up near grain boundaries, eventually making the grain boundaries susceptible to fatigue crack initiation. The mechanisms inferred from the microstructural investigation were extremely valuable in interpreting the influence of prior monotonic straining on the subsequent fatigue life of Inconel 718 superalloy.

Source record↗

NASA NTRS2004

Strain-Gage Loads Calibration Parametric Study

This paper documents a parametric study of various aircraft wing-load test features that affect the quality of the resultant derived shear, bending-moment, and torque strain-gage load equations. The effect of the following on derived strain-gage equation accuracy are compared: single-point loading compared with distributed loading, variation in applied test load magnitude, number of applied load cases, and wing-box-only compared with control-surface loading. The subject of this study is an extensive wing-load calibration test of the Active Aeroelastic Wing F/A-18 airplane. Selected subsets of the available test data were used to derive load equations using the linear regression method. Results show the benefit of distributed loading and the diminishing-return benefits of test load magnitudes and number of load cases. The use of independent check cases as a quality metric for the derived load equations is shown to overcome blind extrapolating beyond the load data used to derive the load equations.

Lokos, William A.↗

NASA NTRS1979

The role of crack blunting in sustained load crack growth

Sustained load crack growth occurs in metals following critical crack extension above KIc and in aggressive environments while maintaining a constant load below KIc. In this paper, crack arrest measurements are performed on precracked, 0.0254-m thick, side-grooved WOL specimens exposed to 34.5 MN/sq m hydrogen at ambient temperature. The specimens are loaded inside a pressure vessel while in contact with the high pressure hydrogen environment. Crack growth is observed with each loading increment. The crack blunting observed in the fracture mechanics tests on 321 stainless steel is found to be similar to that produced in the 321 stainless steel tensile specimens. Rounding and branching of the crack decreases the effective stress intensity at the crack tip. It is possible, for materials in which cracks tend to blunt or branch in hydrogen, that although cracks will arrest at a relatively high stress intensity in decreasing stress intensity test, a crack may begin to grow at a lower stress intensity when loaded in hydrogen, and the crack may continue to grow when the stress intensity is continually increasing.

Walter, R. J.↗

NASA NTRS1983

On the solution of elastic-plastic static and dynamic postbuckling collapse of general structure

Many investigations have considered structural collapse from strictly the transient point of view. While such an approach is ideally correct, certain difficulties have to be overcome in its implementation. The present investigation is concerned with the development of self-adaptive algorithms which make it possible to conduct the analysis of both static elastic and elastic-plastic postbuckling, as well as static loading to the onset of buckling followed by subsequent dynamic postbuckling. The approach employed to solve the static portion of loading is to extend the constrained Incremental Newton-Raphson (INR) algorithm by incorporating elastic-plastic constitutive characterizations. Large deformation moderate strain theory is adopted to establish the overall strategy. Attention is given to governing field equations, aspects of algorithmic development, and numerical experiments conducted to illustrate the efficiency and stability of the developed schemes.

Padovan, J.↗

NASA NTRS1998

Optimization of Supersonic Transport Trajectories

This paper develops a near-optimal guidance law for generating minimum fuel, time, or cost fixed-range trajectories for supersonic transport aircraft. The approach uses a choice of new state variables along with singular perturbation techniques to time-scale decouple the dynamic equations into multiple equations of single order (second order for the fast dynamics). Application of the maximum principle to each of the decoupled equations, as opposed to application to the original coupled equations, avoids the two point boundary value problem and transforms the problem from one of a functional optimization to one of multiple function optimizations. It is shown that such an approach produces well known aircraft performance results such as minimizing the Brequet factor for minimum fuel consumption and the energy climb path. Furthermore, the new state variables produce a consistent calculation of flight path angle along the trajectory, eliminating one of the deficiencies in the traditional energy state approximation. In addition, jumps in the energy climb path are smoothed out by integration of the original dynamic equations at constant load factor. Numerical results performed for a supersonic transport design show that a pushover dive followed by a pullout at nominal load factors are sufficient maneuvers to smooth the jump.

Ardema, Mark D.↗

NASA NTRS1998

Development of Advanced Methods of Structural and Trajectory Analysis for Transport Aircraft

Ardema, Mark D.↗

NASA NTRS1989

Probabilistic structural analysis: Introductory remarks

The development of probabilistic structural analysis methodology consists of the following program elements: (1) composite load spectra models, (2) computational probabilistic structural analysis methods, and (3) probabilistic constitutive relationships. The development of the probabilistic structural analysis methodology is a joint program of NASA Lewis in-house and sponsored research. The objective of this session is to illustrate recent progress on the application of this methodology to determine the reliability of structural components for rocket propulsion systems. The session contains descriptions of and progress reports on the following specific activities: (1) The NESSUS computer code, (2) approximate methods, (3) advanced methods, (4) composite load spectra applications, (5) probabilistic fracture mechanisms, and (6) probability of failure and risk analysis. Collectively, the progress to date demonstrates that the structural durability of hot engine structural components can be effectively evaluated in a formal probabilistic/reliability framework.

Chamis, Christos C.↗

NASA NTRSDate not supplied

Statistically Consistent Dispersions of Line Loads to Uncertain Integrated Forces and Moments

This work presents a method to generate line loads that are consistent with integrated force and moment constraints, while also following the statistical distribution underlying known line load data. The motivation for this method is to address a particular problem that can arise during the pre-flight analysis of an ascent vehicle. That problem is constructing separate databases, for line loads and integrated aerodynamic coefficients, that contain different data and thus different amounts of quantified uncertainty. A dispersed line load method is described and applied to a data set generated by 29 computational fluid dynamics simulations at various angles of attack and sideslip. The statistical similarity of the generated line loads to the known data is confirmed by using the Maximum Mean Discrepancy 2-sample test. The promising results from this novel method are compared against results from applying an existing line load adjustment procedure to the same data set. Finally, potential future avenues of research are briefly discussed.

Aaron C. Burkhead↗

NASA NTRS1977

Load control system

The load control system developed for the shuttle external structural tests is described. The system consists of a load programming/display module, and a load control module along with the following hydraulic system components: servo valves, dump valves, hydraulic system components, and servo valve manifold blocks. One load programming/display subsystem can support multiple load control subsystem modules.

Grosse, J. C.↗

NASA NTRS1975

Determination of rotor harmonic blade loads from acoustic measurements

The magnitude of discrete frequency sound radiated by a rotating blade is strongly influenced by the presence of a nonuniform distribution of aerodynamic forces over the rotor disk. An analytical development and experimental results are provided for a technique by which harmonic blade loads are derived from acoustic measurements. The technique relates, on a one-to-one basis, the discrete frequency sound harmonic amplitudes measured at a point on the axis of rotation to the blade-load harmonic amplitudes. This technique was applied to acoustic data from two helicopter types and from a series of test results using the NASA-Langley Research Center rotor test facility. The inferred blade-load harmonics for the cases considered tended to follow an inverse power law relationship with harmonic blade-load number. Empirical curve fits to the data showed the harmonic fall-off rate to be in the range of 6 to 9 db per octave of harmonic order. These empirical relationships were subsequently used as input data in a compatible far field rotational noise prediction model. A comparison between predicted and measured off-axis sound harmonic levels is provided for the experimental cases considered.

Kasper, P. K.↗

NASA NTRS1971

An experimental study of the mechanism of failure of rocks under borehole jack loading

Laboratory and field tests with an experimental jack and an NX-borehole jack are reported. The following conclusions were made: Under borehole jack loading, a circular opening in a brittle solid fails by tensile fracturing when the bearing plate width is not too small. Two proposed contact stress distributions can explain the mechanism of tensile fracturing. The contact stress distribution factor is a material property which can be determined experimentally. The borehole tensile strength is larger than the rupture flexural strength. Knowing the magnitude and orientation of the in situ stress field, borehole jack test results can be used to determine the borehole tensile strength. Knowing the orientation of the in situ stress field and the flexural strength of the rock substance, the magnitude of the in situ stress components can be calculated. The detection of very small cracks is essential for the accurate determination of the failure loads which are used in the calculation of strengths and stress components.

Van, T. K.↗

NASA NTRS1987

Probabilistic structural analysis to evaluate the structural durability of SSME critical components

NASA Lewis Research Center is currently developing probabilistic structural analysis methods for select Space Shuttle Main Engine (SSME) structural components. Briefly, the deterministic, three-dimensional, inelastic analysis methodology developed under the Hot Section Technology (HOST) and R and T Base Programs is being augmented to accommodate the complex probabilistic loading spectra, the thermoviscoplastic material behavior, and the material degradation associated with the environment of space propulsion system structural components representative of the SSME such as turbine blades, transfer ducts, and liquid-oxygen posts. The development of probabilistic structural analysis methodology consists of the following program elements: (1) composite load spectra; (2) probabilistic structural analysis methods; (3) probabilistic finite element theory - new variational principles; and (4) probabilistic structural analysis application. In addition, the program includes deterministic analysis elements: (1) development of structural tailoring computer codes (SSME/STAEBL); (2) development of dynamic creep buckling/ratcheting theory; (3) evaluation of the dynamic characteristics of single-crystal SSME blades; (4) development of SSME blade damper technology; and (5) development of integrated boundary elements for hotfluid structure interaction.

Chamis, Christos C.↗

NASA NTRS1989

Results of the Round Robin on opening-load measurement conducted by ASTM Task Group E24.04.04 on Crack Closure Measurement and Analysis

An experimental Round Robin on the measurement of the opening load in fatigue crack growth tests was conducted on Crack Closure Measurement and Analysis. The Round Robin evaluated the current level of consistency of opening load measurements among laboratories and to identify causes for observed inconsistency. Eleven laboratories participated in the testing of compact and middle-crack specimens. Opening-load measurements were made for crack growth at two stress-intensity factor levels, three crack lengths, and following an overload. All opening-load measurements were based on the analysis of specimen compliance data. When all of the results reported (from all participants, all measurement methods, and all data analysis methods) for a given test condition were pooled, the range of opening loads was very large--typically spanning the lower half of the fatigue loading cycle. Part of the large scatter in the reported opening-load results was ascribed to consistent differences in results produced by the various methods used to measure specimen compliance and to evaluate the opening load from the compliance data. Another significant portion of the scatter was ascribed to lab-to-lab differences in producing the compliance data when using nominally the same method of measurement.

Phillips, Edward P.↗

NASA NTRS2004

Activity-Centric Approach to Distributed Programming

The first phase of an effort to develop a NASA version of the Cybele software system has been completed. To give meaning to even a highly abbreviated summary of the modifications to be embodied in the NASA version, it is necessary to present the following background information on Cybele: Cybele is a proprietary software infrastructure for use by programmers in developing agent-based application programs [complex application programs that contain autonomous, interacting components (agents)]. Cybele provides support for event handling from multiple sources, multithreading, concurrency control, migration, and load balancing. A Cybele agent follows a programming paradigm, called activity-centric programming, that enables an abstraction over system-level thread mechanisms. Activity centric programming relieves application programmers of the complex tasks of thread management, concurrency control, and event management. In order to provide such functionality, activity-centric programming demands support of other layers of software. This concludes the background information. In the first phase of the present development, a new architecture for Cybele was defined. In this architecture, Cybele follows a modular service-based approach to coupling of the programming and service layers of software architecture. In a service-based approach, the functionalities supported by activity-centric programming are apportioned, according to their characteristics, among several groups called services. A well-defined interface among all such services serves as a path that facilitates the maintenance and enhancement of such services without adverse effect on the whole software framework. The activity-centric application-program interface (API) is part of a kernel. The kernel API calls the services by use of their published interface. This approach makes it possible for any application code written exclusively under the API to be portable for any configuration of Cybele.

Levy, Renato↗

NASA NTRS2015

Advanced Stirling Convertor Dual Convertor Controller Testing at NASA Glenn Research Center in the Radioisotope Power Systems System Integration Laboratory

NASA Glenn Research Center (GRC) developed a non-nuclear representation of a Radioisotope Power System (RPS) consisting of a pair of Advanced Stirling Convertors (ASC), a Dual Convertor Controller (DCC) EM (engineering model) 2 & 3, and associated support equipment, which were tested in the Radioisotope Power Systems System Integration Laboratory (RSIL). The DCC was designed by the Johns Hopkins University/Applied Physics Laboratory (JHU/APL) to actively control a pair of Advanced Stirling Convertors (ASC). The first phase of testing included a Dual Advanced Stirling Convertor Simulator (DASCS) which was developed by JHU/APL and simulates the operation and electrical behavior of a pair of ASC's in real time via a combination of hardware and software. RSIL provides insight into the electrical interactions between a representative radioisotope power generator, its associated control schemes, and realistic electric system loads. The first phase of integration testing included the following spacecraft bus configurations: capacitive, battery, and supercapacitor. A load profile, created based on data from several missions, tested the RPS and RSIL ability to maintain operation during load demands above and below the power provided by the RPS. The integration testing also confirmed the DCC's ability to disconnect from the spacecraft when the bus voltage dipped below 22 V or exceeded 36 V. Once operation was verified with the DASCS, the tests were repeated with actual operating ASC's. The goal of this integration testing was to verify operation of the DCC when connected to a spacecraft and to verify the functionality of the newly designed RSIL. The results of these tests are presented in this paper.

systems integration↗

NASA NTRS1974

Bifurcation analysis of the onset of necking in an elastic/plastic cylinder under uniaxial tension

The bifurcation problem governing the onset of axisymmetric necking in a circular cylindrical specimen in uniaxial tension is analysed. The specimen is made of an incompressible elastic/plastic material. One end is subject to a prescribed uniform axial displacement relative to the other and both ends are shear free. The true stress at bifurcation is greater than the stress at which the maximum load is attained by an amount which depends on (a) the radius to length ratio of the specimen, (b) the ratio of the elastic shear modulus to the tangent modulus, and (c) the derivative of the tangent modulus with respect to the stress. Bifurcation takes place immediately following attainment of the maximum load when the specimen is sufficiently slender.

Hutchinson, J. W.↗

NASA NTRS1984

Application of panel method to wake vortex/wing interaction and comparison with experiment

The ability of a low-order panel method to calculate the aerodynamic loads on wings caused by interaction with wake vortices was studied. The loads were calculated for various positions of a downstream following wing relative to an upstream vortex-generating wing. Calculated vortex-induced span loads and rolling-moment coefficients on the following wing were compared with experimental data. A good agreement with experiment was obtained when the following wing was located more than one following-wing chord length from the tip vortex. The predictions deteriorated as the following wing was placed closer to the vortex. At large downstream distances (approximately 10 generating-wing chord lengths), induced rolling-moment coefficients on the following wing were consistently overestimated. Despite the strong interaction between the wake-vortex filaments and surface doublet panels, the accuracy of the calculations was in most cases independent of the panel distribution and density. A good agreement between theoretical and experimental loads was obtained with a minimum of experimentation with panel arrangements.

Smith, B. E.↗

NASA NTRS1961

Flight-Path Characteristics for Decelerating From Supercircular Speed

Characteristics of the following six flight paths for decelerating from a supercircular speed are developed in closed form: constant angle of attack, constant net acceleration, constant altitude" constant free-stream Reynolds number, and "modulated roll." The vehicles were required to remain in or near the atmosphere, and to stay within the aerodynamic capabilities of a vehicle with a maximum lift-drag ratio of 1.0 and within a maximum net acceleration G of 10 g's. The local Reynolds number for all the flight paths for a vehicle with a gross weight of 10,000 pounds and a 600 swept wing was found to be about 0.7 x 10(exp 6). With the assumption of a laminar boundary layer, the heating of the vehicle is studied as a function of type of flight path, initial G load, and initial velocity. The following heating parameters were considered: the distribution of the heating rate over the vehicle, the distribution of the heat per square foot over the vehicle, and the total heat input to the vehicle. The constant G load path at limiting G was found to give the lowest total heat input for a given initial velocity. For a vehicle with a maximum lift-drag ratio of 1.0 and a flight path with a maximum G of 10 g's, entry velocities of twice circular appear thermo- dynamically feasible, and entries at velocities of 2.8 times circular are aerodynamically possible. The predominant heating (about 85 percent) occurs at the leading edge of the vehicle. The total ablated weight for a 10,000-pound-gross-weight vehicle decelerating from an initial velocity of twice circular velocity is estimated to be 5 percent of gross weight. Modifying the constant G load flight path by a constant-angle-of-attack segment through a flight- to circular-velocity ratio of 1.0 gives essentially a "point landing" capability but also results in an increased total heat input to the vehicle.

Luidens, Roger W.↗