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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Space Shuttle Crawler Transporter Vibration Analysis in Support of Rollout Fatigue Load Spectra Verification Program

The Crawler Transporter (CT), designed and built for the Apollo Program in the 1960's and surpassing its initial operational life, has become an integral part of the Space Shuttle Program (SSP). The CT transports the Space Shuttle Vehicle (SSV) stack, atop the Mobile Launch Platform (MLP), from the Vehicle Assembly Building (VAB) to the launch pad. This support structure provides hydraulic jacking, leveling and load equalization for the 12 million pound stack on its 3.5-5.0 mile rollout to the launch pad. Major elements of the SSV, consisting of the orbiter, solid rocket boosters (SRB) and external tank (ET) have required fatigue analyses as part of the mission life certification. Compared to rollout vibration, the SSV sees relatively high vibration loads during launch, ascent, descent and landing phases of the mission. Although preliminary measured SRB vibration levels during rollout were of low amplitude and frequency, the duration of the rollout phase is typically high, from 5-6 hours. As part of an expanded mission life assessment, additional certification effort was initiated to define fatigue load spectra for rollout. This study addresses the CT vibration analyses in support of the rollout fatigue study. Structural models developed for modal and vibration analyses were used to identify unique CT, CT/MLP and CT/MLP/SRB vibration characteristics for comparison to instrumented rollout tests. Whereas the main structural and vibration characteristics of the SSV are well defined, minimum analytical and vibration test data on the Crawler Transporter were available. Unique vibration characteristics of the CT are attributable to the drive mechanism, hydraulic jacking system, structural framing and the CT-to-MLP support pad restraints. Initial tests performed on the CT/MLP/SRB configuration showed reasonable correlation with predicted mode shapes and frequencies.

Margasahayam, Ravi N.↗
NASA NTRS2017

Guidelines for VCCT-Based Interlaminar Fatigue and Progressive Failure Finite Element Analysis

This document is intended to detail the theoretical basis, equations, references and data that are necessary to enhance the functionality of commercially available Finite Element codes, with the objective of having functionality better suited for the aerospace industry in the area of composite structural analysis. The specific area of focus will be improvements to composite interlaminar fatigue and progressive interlaminar failure. Suggestions are biased towards codes that perform interlaminar Linear Elastic Fracture Mechanics (LEFM) using Virtual Crack Closure Technique (VCCT)-based algorithms [1,2]. All aspects of the science associated with composite interlaminar crack growth are not fully developed and the codes developed to predict this mode of failure must be programmed with sufficient flexibility to accommodate new functional relationships as the science matures.

Deobald, Lyle R.↗
NASA NTRS2024

On the Validity of the Tada Stress Intensity Factor Solution for the Single Edge Notch Tension Specimen With Pinned Ends

The validity of the Tada stress intensity factor (K Tada ) for pinned-ends single edge notch tension [SEN(T)] specimens is assessed via a combined experimental-modeling approach. Analysis of fatigue crack growth rate reductions during constant-∆K Tada loading demonstrates that specific combinations of alloy stiffness, geometry, and loading result in the true K deviating below K Tada . Geometrically non-linear, 3-dimensional finite element calculations confirm mild-to-strong influences of these parameters, which are not captured by K Tada . Most existing pinned SEN(T) data are found to use parameters where KTada is not significantly reduced, but the present results underscore the need for a more broadly applicable K solution.

Non-linear FEA↗
NASA NTRS2005

Fatigue Crack Growth Database for Damage Tolerance Analysis

The objective of this project was to begin the process of developing a fatigue crack growth database (FCGD) of metallic materials for use in damage tolerance analysis of aircraft structure. For this initial effort, crack growth rate data in the NASGRO (Registered trademark) database, the United States Air Force Damage Tolerant Design Handbook, and other publicly available sources were examined and used to develop a database that characterizes crack growth behavior for specific applications (materials). The focus of this effort was on materials for general commercial aircraft applications, including large transport airplanes, small transport commuter airplanes, general aviation airplanes, and rotorcraft. The end products of this project are the FCGD software and this report. The specific goal of this effort was to present fatigue crack growth data in three usable formats: (1) NASGRO equation parameters, (2) Walker equation parameters, and (3) tabular data points. The development of this FCGD will begin the process of developing a consistent set of standard fatigue crack growth material properties. It is envisioned that the end product of the process will be a general repository for credible and well-documented fracture properties that may be used as a default standard in damage tolerance analyses.

Metallic materials↗
NASA NTRS1989

Application of fracture mechanics and half-cycle theory to the prediction of fatigue life of aerospace structural components

The service life of aircraft structural components undergoing random stress cycling was analyzed by the application of fracture mechanics. The initial crack sizes at the critical stress points for the fatigue crack growth analysis were established through proof load tests. The fatigue crack growth rates for random stress cycles were calculated using the half-cycle method. A new equation was developed for calculating the number of remaining flights for the structural components. The number of remaining flights predicted by the new equation is much lower than that predicted by the conventional equation. This report describes the application of fracture mechanics and the half-cycle method to calculate the number of remaining flights for aircraft structural components.

Ko, William L.↗
DOE OSTI2025

ECAR-8446 Rev 0 MARVEL BPVC Section III Division 5 HBB Fatigue Acceptance Tests

The objective of this analysis is to evaluate the fatigue and creep behavior of 316 SS materials used in the Primary Coolant System (PCS) and Guard Vessel System (GVS) for the first two years of MARVEL reactor operation. The analysis follows the requirements set forth in ASME BPVC Section III, Division 5, HBB-2800, which mandates a fatigue test if operational conditions exceed allowable thresholds. By determining whether the materials meet the HBB-T-1324(a) and HBB-T-1324(b) criteria, this evaluation establishes whether a fatigue test is necessary, as well as the maximum allowable operational hours and temperatures before fatigue testing would be required. The deliverables of this analysis include calculations validating compliance with fatigue acceptance criteria, determination of maximum operational limits for the two-year period, and identification of conditions under which a fatigue test would be necessary. This ensures that the PCS and GVS can operate safely without premature material degradation and align with the design life requirements outlined in SPC-70731. Additionally, this evaluation provides conservative estimates for Service Level B occurrences and their impact on allowable Service Level A hours and temperatures, offering guidance for future operational assessments and potential life extensions beyond the initial two-year period.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
NASA NTRS1973

Methods for structural design at elevated temperatures

A procedure which can be used to design elevated temperature structures is discussed. The desired goal is to have the same confidence in the structural integrity at elevated temperature as the factor of safety gives on mechanical loads at room temperature. Methods of design and analysis for creep, creep rupture, and creep buckling are presented. Example problems are included to illustrate the analytical methods. Creep data for some common structural materials are presented. Appendix B is description, user's manual, and listing for the creep analysis program. The program predicts time to a given creep or to creep rupture for a material subjected to a specified stress-temperature-time spectrum. Fatigue at elevated temperature is discussed. Methods of analysis for high stress-low cycle fatigue, fatigue below the creep range, and fatigue in the creep range are included. The interaction of thermal fatigue and mechanical loads is considered, and a detailed approach to fatigue analysis is given for structures operating below the creep range.

Ellison, A. M.↗
NASA NTRS1987

Prediction of service life of aircraft structural components using the half-cycle method

The service life of aircraft structural components undergoing random stress cycling was analyzed by the application of fracture mechanics. The initial crack sizes at the critical stress points for the fatigue-crack growth analysis were established through proof load tests. The fatigue-crack growth rates for random stress cycles were calculated using the half-cycle method. A new equation was developed for calculating the number of remaining flights for the structural components. The number of remaining flights predicted by the new equation is much lower than that predicted by the conventional equation.

Ko, William L.↗
NASA NTRSDate not supplied

Validation of Delamination Growth Predictions under Fatigue Loading using the Single Leg Bending Specimen

The Single Leg Bending Specimen (SLB) was chosen for a study to compare experimentally determined delamination growth with analysis predictions. First, fatigue tests were performed on SLB specimens with several different starter delamination lengths. Specimens were cycled in load control and delamination length increase was continuously recorded with increasing number of cycles. Test results from different load levels were combined to capture the entire delamination growth law (Paris Law) over a wide range of energy release rates. Second, a recently developed interpolation scheme was used to predict the Paris Law associated with the SLB specimen. This interpolation scheme allows the calculation of the growth rates for a given mixed-mode ratio from known single-mode growth laws. Third, finite element analyses were performed using two-dimensional models of the SLB specimen. New Virtual Crack Closure Technique based analysis tools for automated delamination growth analysis under cyclic loading in Abaqus were used for growth predictions. Fourth, the predictions from analyses were compared to experimental fatigue data. Remaining analysis shortcomings were highlighted.

Ronald Krueger↗
DOE OSTI2022

Using real-time data analysis to conduct next-generation synchrotron fatigue studies

Next-generation experimental techniques, like high energy X-ray diffraction microscopy (HEDM), usher in new opportunities to collect the grain-scale data necessary for understanding the evolving processes that drive fatigue failure. In this study, we present a framework for monitoring the evolution of a deforming polycrystal, in real-time, by applying principal component analysis (PCA) to raw X-ray diffraction image data. We applied this framework to inform in-situ HEDM measurements of a cyclically loaded Inconel-718 superalloy. Further, we discovered correlations between PCA of the diffraction data and the physical processes in the polycrystal. Lastly, we discuss extending this framework in future HEDM fatigue studies.

36 MATERIALS SCIENCE↗
NASA NTRS1969

Probabilistic-graphical and phenomenological analysis of combined bending-torsion fatigue reliability data

Fatigue data generated by three combined bending-torsion fatigue reliability research machines at The University of Arizona are probabilistic-graphically and phenomenologically analyzed. Distributions that are applicable to fatique life and static strength data are discussed. Phenomenological justifications for the use of these distributions are presented. It is found that the normal distribution represents the cycles-to-failure data at the highest stress levels best. The lognormal distribution appears to fit the cycles-to-failure data at the lower stress levels best and quite well at all stress levels including the highest. A regression analysis and least-squares goodness-of-fit test was performed for normal and lognormal plots. In most cases, the correlation coefficient gave a better fit to the data using the normal distribution, but the difference between the two was so slight that positive discrimination could not be made.

Kececioglu, D.↗
NASA NTRS1993

An analysis of isothermal, bithermal, and thermomechanical fatigue data of Haynes 188 and B1900+Hf by energy considerations

The low-cycle fatigue behavior of Haynes 188 and B1900+Hf under isothermal, bithermal, and thermomechanical loading conditions has been analyzed on the basis of the total hysteresis energy expended per cycle. It has been observed that in the case of isothermal fatigue the total hysteresis energy correlates well with the fatigue life. In the case of bithermal 'high rate' fatigue, for a given total hysteresis energy per cycle, the fatigue life is equal to or greater than the isothermal fatigue life at the maximum bithermal temperature. This observation could be used to establish a lower bound on life for design purposes. In one case of bithermal creep-fatigue and in thermomechanical fatigue, the life is shorter than that corresponding to the isothermal life at the maximum temperature. The energy supplied, per se, may not always give a systematic correlation with the fatigue life in the cases where time-dependent creep and environmental effects are encountered. Thus, in bithermal creep-fatigue and thermomechanical fatigue, the role of creep and environment and their dependence on the energy supplied have to be properly accounted for before the energy term can be used for life prediction.

Radhakrishnan, V. M.↗
NASA NTRS2014

Mass Reduction: The Weighty Challenge for Exploration Space Flight

Meeting nutritional and acceptability requirements is critical for the food system for an exploration class space mission. However, this must be achieved within the constraints of available resources such as water, crew time, stowage volume, launch mass and power availability.  Due to resource constraints, exploration class missions are not expected to have refrigerators or freezers for food storage, and current per person food mass must be reduced to improve mission feasibility.  The Packaged Food Mass Reduction Trade Study (Stoklosa, 2009) concluded that the mass of the current space food system can be effectively reduced by decreasing water content of certain foods and offering nutrient dense substitutes, such as meal replacement bars and beverages. Target nutrient ranges were established based on the nutritional content of the current breakfast and lunch meals in the ISS standard menu. A market survey of available commercial products produced no viable options for meal replacement bar or beverage products. New prototypes for both categories were formulated to meet target nutrient ranges. Samples of prototype products were packaged in high barrier packaging currently used for ISS and underwent an accelerated shelf life study at 31 degC and 41 degC (50% RH) for 24 weeks. Samples were assessed at the following time points: Initial, 6 weeks, 12 weeks, and 24 weeks. Testing at each time point included the following: color, texture, water activity, acceptability, and hexanal analysis (for food bars only). Proof of concept prototypes demonstrated that meal replacement food bars and beverages can deliver a comparable macronutrient profile while reducing the overall mass when compared to the ISS Standard Menu. Future work suggestions for meal replacement bars: Reformulation to include ingredients that reduce hardness and reduce browning to increase shelf life. Micronutrient analysis and potential fortification. Sensory evaluation studies including satiety tests and menu fatigue. Water Intake Analysis: The water in thermostabilized foods is considered as part of a crewmember's daily water intake. Extensive meal replacement would require further analyses to determine if additional water provisioning would be required per crewmember negating some of the mass savings.

Kloeris, Vickie L.↗
NASA NTRS1978

Characterization of wear debris generated in accelerated rolling-element fatigue tests

A ferrographic analysis was used to determine the types and quantities of wear debris generated during accelerated rolling contact fatigue tests. The five-ball rolling contact fatigue tester was used. Ball specimens were made of a corrosion resistant, high-temperature bearing steel. The lubricant was a superrefined naphthenic mineral oil. Conditions included a maximum Hertz stress of 5.52 10 to the 9th power Pa and a shaft speed of 10,000 rpm. Four types of wear debris were observed: (1) normal rubbing wear particles, (2) fatigue microspall particles, (3) spheres, and (4) friction polymer deposits. The characterization of wear debris as a function of time was of limited use in predicting fatigue failures in these accelerated tests.

Jones, W. R., Jr.↗
DOE OSTI2022

Uncertainty Quantification of Monolithic Tungsten Target Block Fatigue

The current STS spallation target design consists of 21 water cooled, tantalum clad, monolithic tungsten blocks. The target wheel assembly rotates such that each target block receives a direct proton pulse every 1.4 seconds (21 blocks / 15 Hz pulses). The quasi-steady heating induced by the repetitive beam pulses creates a significant mean stress distribution in the target. On top of this, the rapid energy deposition from a proton pulse induces dynamic stress waves that are of the same order of magnitude as the mean stresses. Over the design goal of 5,000 operational hours per year for a decade, each target must withstand over 130 million repetitions of these dynamic stress events. The fatigue life prediction of the target blocks is a complex sequence of simulations that depend upon a set of input parameters. For the tungsten block, the end goal is the fatigue factor-of-safety (FOS). This study documents a new structural analysis routine using software available to U.S. national laboratories (e.g. CUBIT, Sierra Multiphysics, Dakota) that enables more rapid target fatigue analysis. The increased throughput is amenable to parameter sensitivity and uncertainty quantification (UQ) studies. A set of input parameters (ultimate strength, fatigue strength, density, elastic modulus, Poisson’s ratio, thermal conductivity, coefficient of thermal expansion, specific heat, flow rate) with expected ranges are documented based on literature data, recent experimental testing, and engineering judgement. UQ bounds the resulting fatigue FOS at [0.5, 3.4] using epistemic interval analysis. These bounds are expected to be wider due to model effects (discretization) and beam effects (focus, offset) that were not included. Parameter sensitivity underscores the importance of ultimate strength and fatigue strength of irradiated tungsten on the fatigue calculations.

43 PARTICLE ACCELERATORS↗
NASA NTRS2001

Effect of Roller Profile on Cylindrical Roller Bearing Life Prediction: Comparison of Bearing Life Theories - Part 1

Four rolling-element bearing life theories were chosen for analysis and compared for a simple roller-race geometry model. The life theories were those of Weibull; Lundberg and Palmgren; Ioannides and Harris; and Zaretsky. The analysis without a fatigue limit of Ioannides and Harris is identical to the Lundberg and Palmgren analysis, and the Weibull analysis is similar to that of Zaretsky if the exponents are chosen to be identical. The resultant predicted life a each stress condition not only depends on the life equation used but also on the Weibull slope assumed. The least variation in predicted life with Weibull slope comes with the Zaretsky equation. Except for a Weibull slope of 1.11, at which the Weibull equation predicts the highest lives, the highest lives are predicted for the Zaretsky equation. For Weibull slopes of 1.5 and 2, both the Lundherg-Palmgren and Ioannides-Harris (where tau(sub u) = 0) equations predict lower lives than the ANSI/ABMA/ISO standard. Based upon the Hertz stresses for line contact, the accepted load-life exponent of 10/3 results in a maximum Hertz stress-life exponent equal to 6.6. This value is inconsistent with that experienced in the field. The assumption of as shear stress fatigue limit tau(sub u) results in Hertz stress-life exponents greater than are experimentally verifiable.

Poplawski, Joseph V.↗
NASA NTRS1992

Analysis and prediction of Multiple-Site Damage (MSD) fatigue crack growth

A technique was developed to calculate the stress intensity factor for multiple interacting cracks. The analysis was verified through comparison with accepted methods of calculating stress intensity factors. The technique was incorporated into a fatigue crack growth prediction model and used to predict the fatigue crack growth life for multiple-site damage (MSD). The analysis was verified through comparison with experiments conducted on uniaxially loaded flat panels with multiple cracks. Configuration with nearly equal and unequal crack distribution were examined. The fatigue crack growth predictions agreed within 20 percent of the experimental lives for all crack configurations considered.

Dawicke, D. S.↗