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NASA NTRS2026

Fatigue Behavior of Laser Powder Bed Fused HAYNES 214: Effects of Different Surface Treatments

In this study, under NASA’s Rapid and Analysis Manufacturing Propulsion Technology (RAMPT) project, effects of different surface post-treatments on surface texture and fatigue behavior of L-PBF Alloy 214 were investigated. Various subtractive SPTs including abrasive flow machining (AFM), machining (M), shot peening (SP), vapormatt (VM), dry electropolishing (DE), chemical milling (CM), chemical-mechanical polishing (CMP), electro chemical (ECP) were applied to study the variations of the surface texture, microstructure and uniaxial fatigue behavior under fully reversed strain-controlled condition at four different strain amplitudes of 0.005, 0.004, 0.003, and 0.0025 mm/mm. The insights gained regarding the relationship between structural and mechanical properties for different SPTs can help establish guidelines for selecting the most effective process to enhance the performance of Laser Powder Bed Fusion (L-PBF) Alloy 214, especially for critical aerospace applications.

Post-Processing↗

NASA NTRS1990

Through-the-thickness fatigue crack closure behavior in an aluminum alloy

The variation in fatigue crack closure behavior across the thickness of aluminum alloy specimens was investigated. The specimen geometries examined were the middle crack tension M(T) and compact tension C(T). The fatigue crack closure behavior was determined using remote displacement and strain gages, near tip strain gages, and fatigue striations. A hybrid experimental/numerical method was also used to infer the crack opening loads. The results indicate a variation in crack opening load, of 0.2 in the specimen interior to 0.4 to 0.5 at the surface.

Dawicke, D. S.↗

NASA NTRS1990

Through-the-thickness fatigue crack closure behavior in an aluminum alloy

Dawicke, D. S.↗

NASA NTRS2002

Tensile Behavior of As-Fabricated and Burner-Rig Exposed SiC/SiC Composites with Hi-Nicalon Type-S Fibers

Tensile stress-strain curves were measured at room temperature and 1315 C for 2D-woven SiC/BN/SiC ceramic matrix composites (CMC) reinforced by two variations of Hi-Nicalon Type-S SiC fibers. These fibers, which contained a thin continuous carbon-rich layer on their as-produced surface, provided the as-fabricated CMC with good composite behavior and an ultimate strength and strain of -350 MPa and -0.5%, respectively. However, after un-stressed burner-rig exposure at 815 C for -100 hrs, CMC tensile specimens with cut edges and exposed interphases showed a significant decrease in ultimate properties with effectively no composite behavior. Microstructural observations show that the degradation was caused by internal fiber-fiber oxide bonding after removal of the carbon-rich fiber surface layer by the high-velocity combustion gases. On the other hand, SiC/BN/SiC CMC with Sylramic-iBN fibers without carbon-rich surfaces showed higher as-fabricated strength and no loss in strength after the same burner rig exposure. Based on the strong role of the carbon layer in these observations, a process method was developed and demonstrated for achieving better strength retention of Hi-Nicalon Type-S CMC during burner rig exposure. Other general approaches for minimizing this current deficiency with as-produced Type-S fibers are discussed.

Yun, H. M.↗

NASA NTRS2003

A Variational Principle for Reconstruction of Elastic Deformations in Shear Deformable Plates and Shells

A variational principle is formulated for the inverse problem of full-field reconstruction of three-dimensional plate/shell deformations from experimentally measured surface strains. The formulation is based upon the minimization of a least squares functional that uses the complete set of strain measures consistent with linear, first-order shear-deformation theory. The formulation, which accommodates for transverse shear deformation, is applicable for the analysis of thin and moderately thick plate and shell structures. The main benefit of the variational principle is that it is well suited for C(sup 0)-continuous displacement finite element discretizations, thus enabling the development of robust algorithms for application to complex civil and aeronautical structures. The methodology is especially aimed at the next generation of aerospace vehicles for use in real-time structural health monitoring systems.

Tessler, Alexander↗

NASA NTRS1996

Stress Calculations for Carbon Nanotubes

Atomic stresses were calculated for carbon nanotubes under strain conditions. Graphitic tubules with radii ranging from approximately 2 to 11 Angstroms and two different tubule structures with varying atomic orientations were included in the calculations. Elongations and contractions were applied in the axial direction and atomic stress values were calculated for infinitely long tubules. The calculations were carried out using Brenner's function which was developed for carbon species. Results indicate that the stress is tensile in the radial direction while it is compressive in the tangential direction. Variations in stress values in the direction of the cylindrical aids were investigated as a function of applied strain. Furthermore, using the stress-strain curve (calculated based on atomic considerations), the values of Young's modulus and Poisson's ratio for nanotubules were also estimated.

Halicioglu, Timur↗

NASA NTRS1980

Calculation of residual principal stresses in CVD boron on carbon filaments

A three-dimensional finite element model of the chemical vapor deposition of boron on a carbon substrate (B/C) is developed. The model includes an expansion of the boron after deposition due to atomic rearrangement and includes creep of the boron and carbon. Curves are presented showing the variation of the principal residual stresses and the filament elongation with the parameters defining deposition strain and creep. The calculated results are compared with experimental axial residual stress and elongation measurements made on B/C filaments. For good agreement between calculated and experimental results, the deposited boron must continue to expand after deposition, and the build up of residual stresses must be limited by significant boron and carbon creep rates.

Behrendt, D. R.↗

NASA NTRS1982

Dynamic response of lined tunnels by boundary elements

The dynamic stress concentration manifested around a lined cylindrical tunnel buried in an infinitely extending linear elastic or viscoelastic medium due to the passage of transient disturbances was investigated. Plane strain is assumed to hold and the transient disturbances can be of any arbitrary time variation. The boundary element method formulated in the Laplace transform domain is employed. Isoparametric boundary elements are used in the discretization of the liner and tunnel surfaces. Viscoelastic material behavior can be readily obtained from the linear elastic case in the Laplace transform domain through the use of the correspondence principle. The transient solution is recovered by numerical inversion of the solution obtained in the transformed domain.

Manolis, G. D.↗

NASA NTRS1993

A nonlinear theory for spinning anisotropic beams using restrained warping functions

A geometrically nonlinear theory is developed for spinning anisotropic beams having arbitrary cross sections. An assumed displacement field is developed using the standard 3D kinematics relations to describe the global beam behavior supplemented with an additional field that represents the local deformation within the cross section and warping out of the cross section plane. It is assumed that the magnitude of this additional field is directly proportional to the local stress resultants. In order to take into account the effects of boundary conditions, a restraining function is introduced. This function plays the role of reducing the amount of free warping deformation throughout the field due to the restraint of the cross section(s) at the end(s) of the beam, e.g., in the case of a cantilever beam. Using a developed ordering scheme, the nonlinear strains are calculated to the third order. The FEM is developed using the weak form variational formulation. Preliminary interesting numerical results have been obtained that indicate the role of the restraining function in the case of a cantilever beam with circular cross section. These results are for the cases of a tip displacement (static) and free vibration studies for both isotropic and anisotropic materials with varied fiber orientations.

Ie, C. A.↗

NASA NTRS1997

Neural Network Prediction of Failure of Damaged Composite Pressure Vessels from Strain Field Data Acquired by a Computer Vision Method

This effort used a new and novel method of acquiring strains called Sub-pixel Digital Video Image Correlation (SDVIC) on impact damaged Kevlar/epoxy filament wound pressure vessels during a proof test. To predict the burst pressure, the hoop strain field distribution around the impact location from three vessels was used to train a neural network. The network was then tested on additional pressure vessels. Several variations on the network were tried. The best results were obtained using a single hidden layer. SDVIC is a fill-field non-contact computer vision technique which provides in-plane deformation and strain data over a load differential. This method was used to determine hoop and axial displacements, hoop and axial linear strains, the in-plane shear strains and rotations in the regions surrounding impact sites in filament wound pressure vessels (FWPV) during proof loading by internal pressurization. The relationship between these deformation measurement values and the remaining life of the pressure vessels, however, requires a complex theoretical model or numerical simulation. Both of these techniques are time consuming and complicated. Previous results using neural network methods had been successful in predicting the burst pressure for graphite/epoxy pressure vessels based upon acoustic emission (AE) measurements in similar tests. The neural network associates the character of the AE amplitude distribution, which depends upon the extent of impact damage, with the burst pressure. Similarly, higher amounts of impact damage are theorized to cause a higher amount of strain concentration in the damage effected zone at a given pressure and result in lower burst pressures. This relationship suggests that a neural network might be able to find an empirical relationship between the SDVIC strain field data and the burst pressure, analogous to the AE method, with greater speed and simplicity than theoretical or finite element modeling. The process of testing SDVIC neural network analysis and some encouraging preliminary results are presented in this paper. Details are given concerning the processing of SDVIC output data such that it may be used as back propagation neural network (BPNN) input data. The software written to perform this processing and the BPNN algorithm are also discussed. It will be shown that, with limited training, test results indicate an average error in burst pressure prediction of approximately six percent,

Russell, Samuel S.↗

NASA NTRS2019

Verification and Validation of a Three-Dimensional Composite Impact Model with Tabulated Input

A material model which incorporates several key capabilities which have been identified by the aerospace community as lacking in the composite impact models currently available in the commercial transient dynamic finite element code LS-DYNA® has been developed. The material model utilizes experimentally based tabulated input to define the evolution of plasticity and damage as opposed to specifying discrete input parameters (such as modulus and strength. The plasticity portion of the orthotropic, three-dimensional, macroscopic composite constitutive model is based on an extension of the Tsai-Wu composite failure model into a generalized yield function with a non-associative flow rule. The capability to account for the rate and temperature dependent deformation response of composites has also been incorporated into the material model. For the damage model, a strain equivalent formulation is utilized to allow for the uncoupling of the deformation and damage analyses. In the damage model, a diagonal damage tensor is defined to account for the directionally dependent variation of damage. However, the terms in the damage matrix are semi-coupled such that the damage in a particular coordinate direction is a function of the stresses and plastic strains in all of the coordinate directions. For the failure model, a tabulated approach is utilized in which a stress or strain based invariant is defined as a function of the location of the current stress state in stress space to define the initiation of failure, which allows an arbitrarily shaped failure surface to be defined. A systematic series of validation and verification studies, at a variety of length scales ranging from single element simulations to simulations of a flat panel impact test, have been performed to fully exercise and evaluate the capabilities of the developed model.

Impact↗

NASA NTRS2004

Nonlinear Analysis of Bonded Composite Single-LAP Joints

This study presents a semi-analytical solution method to analyze the geometrically nonlinear response of bonded composite single-lap joints with tapered adherend edges under uniaxial tension. The solution method provides the transverse shear and normal stresses in the adhesive and in-plane stress resultants and bending moments in the adherends. The method utilizes the principle of virtual work in conjunction with von Karman s nonlinear plate theory to model the adherends and the shear lag model to represent the kinematics of the thin adhesive layer between the adherends. Furthermore, the method accounts for the bilinear elastic material behavior of the adhesive while maintaining a linear stress-strain relationship in the adherends. In order to account for the stiffness changes due to thickness variation of the adherends along the tapered edges, their in-plane and bending stiffness matrices are varied as a function of thickness along the tapered region. The combination of these complexities results in a system of nonlinear governing equilibrium equations. This approach represents a computationally efficient alternative to finite element method. Comparisons are made with corresponding results obtained from finite-element analysis. The results confirm the validity of the solution method. The numerical results present the effects of taper angle, adherend overlap length, and the bilinear adhesive material on the stress fields in the adherends, as well as the adhesive, of a single-lap joint

Oterkus, E.↗

NASA NTRS2004

Inverse FEM for Full-Field Reconstruction of Elastic Deformations in Shear Deformable Plates and Shells

The inverse problem of real-time reconstruction of full-field structural displacements is addressed through the application of a new variational formulation leading to versatile, robust and computationally efficient inverse shell finite element analysis. Utilizing surface strain measurements from strain sensors mounted on the load-carrying structural components, the methodology enables accurate computations of the three-dimensional displacement field. This high fidelity computational technology is essential for providing feedback to the actuation and control systems of the next generation of aerospace vehicles.

Tessler, Alexander↗

NASA NTRS2003

Significance of Strain in Formulation in Theory of Solid Mechanics

The basic theory of solid mechanics was deemed complete circa 1860 when St. Venant provided the strain formulation or the field compatibility condition. The strain formulation was incomplete. The missing portion has been formulated and identified as the boundary compatibility condition (BCC). The BCC, derived through a variational formulation, has been verified through integral theorem and solution of problems. The BCC, unlike the field counterpart, do not trivialize when expressed in displacements. Navier s method and the stiffness formulation have to account for the extra conditions especially at the inter-element boundaries in a finite element model. Completion of the strain formulation has led to the revival of the direct force calculation methods: the Integrated Force Method (IFM) and its dual (IFMD) for finite element analysis, and the completed Beltrami-Michell formulation (CBMF) in elasticity. The benefits from the new methods in elasticity, in finite element analysis, and in design optimization are discussed. Existing solutions and computer codes may have to be adjusted for the compliance of the new conditions. Complacency because the discipline is over a century old and computer codes have been developed for half a century can lead to stagnation of the discipline.

Patnaik, Surya N.↗

NASA NTRS1978

Implications of cavity, topographic and geologic influences on tilt and strain observations

Tilt and strain observations are importantly (pathologically at the 100%, typically at the few 10s% level) affected by cavities, topography, and geological inhomogenities; gravity observation are practically unaffected. The traditional earth tide observatory and abandoned mine or tunnel is a very poor place to measure body tides because of the complicated cavities, topography and geology. Instead, the ideal site for observing the body tide is in flat terrain with horizontally layered, mechanically homogeneous geology. Strain will be measured with long surface- or trench-mounted laser strain meters and tilt with long, surface- or trench mounted liquid levels, or with borehole tiltmeters. Horizontal geological discontinuities can produce large perturbations of the tilt and strain tides, and these perturbations, using the known homogeneous tidal strains and tilts, can be used in exploring local structure in favorable cases and, through possible time variations of tidal admittances, in predicting earthquakes.

Harrison, J. C.↗

NASA NTRS1979

Thermal cycling graphite-polyimide

The effects of repetitive thermal cycling on the temperature-thermal deformation relation of graphite-polyimide were determined. The bending and axial strains, measured with strain gages, of unsymmetric 0 deg sub 2/90 deg sub 2 and 0 deg sub 4/90 deg sub 4 laminates were used as an indication of thermal deformation. The strains were measured as a function of temperature and two temperature ranges were used, room temperature to 180 C and room temperature to 315 C. Five cycles were run in each temperature range and the cycling was done in quasistatic fashion. The response of a flat 0 deg sub 8 laminate was measured as were the effects of repetitive cycling on the strain gages themselves. A piece-wise linear theory, based on classical lamination theory and using the variation of mechanical and thermal expansion properties with temperature, was compared with the experimental results. The correlation between theoretical predictions and experimental results for the thinner laminate was poor.

Hyer, M. W.↗

NASA NTRS1982

Structures on Europa

Four classes of lineation patterns have been identified on Europa in the area covered by high-resolution Voyager 2 images. These include dark, wedge-shaped bands in the west-central part of the area; triple bands associated with diagonally trending, global lineations; gray concentric curvilinear bands in the southeastern part; and ridges near the terminator. The major structures appear to have been formed by tidal forces centered on the axis pointing toward Jupiter, but variations in the detail of the structural patterns may have been caused by internal forces. The older strain patterns tend to be rejuvenated by younger fractures. The most persistent rejuvenated strain patterns are the global diagonal fractures, probably formed by conjugate shear, and the straight and curvilinear fractures that apparently caused an early dichotomy in fracture patterns.

Lucchitta, B. K.↗

NASA NTRS1990

Three-dimensional crack closure behavior

A crack closure measurement technique involving fatigue striations was used to produce a three-dimensional crack opening load profile for 2024-T351 aluminum alloy. The crack opening load profile, determined through the specimen thickness, was compared with crack opening load measurements made with strain gages and displacement gages. The results of this study indicate that a significant three-dimensional variation in crack closure behavior occurs in the alloy examined. An understanding of this phehomenon is important in understanding crack growth behavior, predicting crack shape changes, and interpreting 'standard' crack closure measurement techniques.

Dawicke, D. S.↗