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Stress wave analysis and crack opening displacement to monitor subcritical crack growth for grade B alloy steel pressure vessels
Because the 2195 aluminum-lithium material of the super lightweight external tank (SLWT ET) has a lower toughness than the 2219 aluminum used in previous ET's, careful attention must be paid to stress concentrations. This report details the analysis performed on some of the stress concentrations in the orthogrid panels of the liquid hydrogen tank.
A friction stir weld (FSW) repair method has been developed and successfully implemented on Al 2195 plate material for the Space Shuttle External Fuel Tank (ET). The method includes restarting the friction stir weld in the termination hole of the original weld followed by two reweld passes. Room temperature and cryogenic temperature mechanical properties exceeded minimum FSW design strength and compared well with the development data. Simulated service test results also compared closely to historical data for initial FSW, confirming no change to the critical flaw size or inspection requirements for the repaired weld. Testing of VPPA fusion/FSW intersection weld specimens exhibited acceptable strength and exceeded the minimum design value. Porosity, when present at the intersection was on the root side toe of the fusion weld, the "worst case" being 0.7 inch long. While such porosity may be removed by sanding, this "worst case" porosity condition was tested "as is" and demonstrated that porosity did not negatively affect the strength of the intersection weld. Large, 15-inch "wide panels" FSW repair welds were tested to demonstrate strength and evaluate residual stresses using photo stress analysis. All results exceeded design minimums, and photo stress analysis showed no significant stress gradients due to the presence of the restart and multi-pass FSW repair weld.
Dynamic animation of stresses and displacements, which complement each other, can be a useful tool in the analysis and design of structural components. At the present time only displacement-mode animation is available through the popular stiffness formulation. This paper attempts to complete this valuable visualization tool by augmenting the existing art with stress mode animation. The reformulated method of forces, which in the literature is known as the integrated force method (IFM), became the analyzer of choice for the development of stress mode animation because stresses are the primary unknowns of its dynamic analysis. Animation of stresses and displacements, which have been developed successfully through the IFM analyzers, is illustrated in several examples along with a brief introduction to IFM dynamic analysis. The usefulness of animation in design optimization is illustrated considering the spacer structure component of the International Space Station as an example. An overview of the integrated force method analysis code (IFM/ANALYZERS) is provided in the appendix.
During the time frame allocated by the delivery order, members of the UAH Applied Research Program, with the cooperation of representatives from NASA investigated and conducted stress analysis of the SEDSAT1 satellite. The main area of concern was with the design of the deployable 10 m antennas. The placement of the holes for the antenna door hinge pin was too close to the edge of the antenna canister. Because of the load placed on the hinge pin, the stress analysis of this area suggested that more space would be needed between the holes and the edge of the material. Due to other conflicts, SEDSATI was removed from flying on the space shuttle and moved to the Delta Launch Vehicle. This changed many of the design requirements for the mounting and deployment of the satellite that forced a new design for the satellite. Once this happened, the stress analysis became obsolete, and the task was concluded.
A variational analysis of the stress state in microcracked cross-ply laminates has been used to investigate the phenomenon of curved microcracking in /(S)/90n/s laminates. Previous investigators proposed that the initiation and orientation of curved microcracks are controlled by local maxima and stress trajectories of the principal stresses. We have implemented a principal stress model using a variational mechanics stress analysis and we were able to make predictions about curved microcracks. The predictions agree well with experimental observations and therefore support the assertion that the variational analysis gives an accurate stress state that is useful for modeling the microcracking properties of cross-ply laminates. An important prediction about curved microcracks is that they are a late stage of microcracking damage. They occur only when the crack density of straight microcracks exceeds the critical crack density for curved microcracking. The predicted critical crack density for curved microcracking agrees well with experimental observations.
A polariscope for the study of the propagation of stress waves in birefringent sheets is described. Sensitive, fast-responding photomultiplier tubes, a laser light source, and a multiple channel oscilloscope were used for the simultaneous recording of the stress-optic data at several points of the target following impact. A method of separation of stresses and the computation of displacement, strain, and stress is given.
A new Rayleigh-Ritz stress analysis methodology that was developed for composite panels containing cutouts is described. The procedure, which makes use of a general assumed displacement field, accommodates circular and elliptical cutouts in biaxially loaded rectangular composite panels. Symmetric integral padups around the cutout can be included in the analysis. Benchmark results are presented to demonstrate the accuracy of the technique. Strength predictions based on the average stress criterion are generated and compared with experimental data. Finally, the stress analysis methodology is integrated into a design procedure for sizing integral padups around circular cutouts, and a sample problem is solved to illustrate its use.
A graphite/bismaleimide laminate was prepared without the usual fiber treatment and was tested over a wide range of stress states to measure its ply cracking strength. These tests were conducted using off-axis flexure specimens and produced fiber-matrix interface failure data over a correspondingly wide range of interface stress states. The absence of fiber treatment, weakened the fiber-matrix interfaces and allowed these tests to be conducted at load levels that did not yield the matrix. An elastic micromechanics computer code was used to calculate the fiber-matrix interface stresses at failure. Two different fiber-array models (square and diamond) were used in these calculations to analyze the effects of fiber arrangement as well as stress state on the critical interface stresses at failure. This study showed that both fiber-array models were needed to analyze interface stresses over the range of stress states. A linear equation provided a close fit to these critical stress combinations and, thereby, provided a fiber-matrix interface failure criterion. These results suggest that prediction procedures for laminate ply cracking can be based on micromechanics stress analyses and appropriate fiber-matrix interface failure criteria. However, typical structural laminates may require elastoplastic stress analysis procedures that account for matrix yielding, especially for shear-dominated ply stress states.
The goal of this work is to predict the mechanical response of TPS materials, and specifically, to determine if there is additional surface recession in the heat shield’s surface as a result of mechanical erosion due to the mechanical and thermal loads experienced during atmospheric entry. To accomplish this, a solid mechanics module was integrated within the PATO material response code, enabling it to model the potential mechanical erosion in three steps: first, having the effective mechanical properties as function of temperature, the implemented stress analysis solver computes the stress and the displacement fields for the TPS material using the wall shear stress tensor, computed with the DPLR hypersonic CFD code, as boundary conditions; then, regions on the surface where the stress meets the failure criteria are identified; finally, the failed material is removed and the mesh is redistributed accordingly. The outcome is a model capable of predicting the total recession in the TPS material due to surface chemistry and mechanical erosion.
The design of a nose cap for a hypersonic vehicle is an iterative process requiring a rapid, easy to use and accurate stress analysis. The objective of this paper is to develop such a stress analysis technique from a direct solution of the thermal stress equations for a spherical shell. The nose cap structure is treated as a thin spherical shell with an axisymmetric temperature distribution. The governing differential equations are solved by expressing the stress solution to the thermoelastic equations in terms of a series of derivatives of the Legendre polynomials. The process of finding the coefficients for the series solution in terms of the temperature distribution is generalized by expressing the temperature along the shell and through the thickness as a polynomial in the spherical angle coordinate. Under this generalization the orthogonality property of the Legendre polynomials leads to a sequence of integrals involving powers of the spherical shell coordinate times the derivative of the Legendre polynomials. The coefficients of the temperature polynomial appear outside of these integrals. Thus, the integrals are evaluated only once and their values tabulated for use with any arbitrary polynomial temperature distribution.
Strength analysis for composite bolted joints involves the mating of a stress analysis with an appropriate mode specific failure criterion for each of the primary failure modes. The stress analysis and failure criteria are independent of each other and can be manipulated separately in order to optimize the strength analysis package formed by their coupling. Material properties tests were conducted on rubber toughened graphite-epoxy material to measure the basic strength and stiffness in the warp and fill directions and in shear. Test matrices are summarized for investigations of laminate configuration, stacking sequence, fastener diameter, edge distance, fastener half spacing, laminate thickness, and fastener torque. A three dimensional finite element analysis computer program was written and failure criteria for net tension, shearout, and bearing were determined.
Stress analysis and functions in membrane analysis of scalloped thin walled shells like parachutes
Stress intensities calculated in bending and tension. Finite-element stress-analysis method gives stress-intensity estimates for surface flaws on smooth and threaded round bars. Calculations done for purely tensile and purely bending loads. Results, presented in dimensionless form, useful for determining fatigue lives of bolts and pins.
Temperature profiles for silicon ribbon are presented. Ribbon dislocations and elastic stress are discussed. Ribbon quality is important for the ribbon's function as a solar cell.
Because the 2195 aluminum-lithium of the super lightweight external tank (SLWT ET) has a lower toughness than the 2219 aluminum used in previous ET's, careful attention must be paid to stress concentration in the SLWT ET. This report details the initial analysis performed by NASA to determine the material properties required to ensure structural integrity in these critical areas.
Computational techniques were developed and assimilated for the design optimization. The resulting computer program was then used to perform initial optimization and sensitivity studies on a typical thermal protection system (TPS) to demonstrate its application to the space shuttle TPS design. The program was developed in Fortran IV for the CDC 6400 but was subsequently converted to the Fortran V language to be used on the Univac 1108. The program allows for improvement and update of the performance prediction techniques. The program logic involves subroutines which handle the following basic functions: (1) a driver which calls for input, output, and communication between program and user and between the subroutines themselves; (2) thermodynamic analysis; (3) thermal stress analysis; (4) acoustic fatigue analysis; and (5) weights/cost analysis. In addition, a system total cost is predicted based on system weight and historical cost data of similar systems. Two basic types of input are provided, both of which are based on trajectory data. These are vehicle attitude (altitude, velocity, and angles of attack and sideslip), for external heat and pressure loads calculation, and heating rates and pressure loads as a function of time.
Development of the plasma sprayed graded, layered ZRO2/CoCrAlY seal system for gas turbine engine blade tip seal applications up to 1589 K (2400 F) surface temperature was continued. The effect of changing ZRO2/CoCrAlY ratios in the intermediate layers on thermal stresses was evaluated analytically with the goal of identifying the materials combinations which would minimize thermal stresses in the seal system. Three methods of inducing compressive residual stresses in the sprayed seal materials to offset tensile thermal stresses were analyzed. The most promising method, thermal prestraining, was selected based upon potential, feasibility and complexity considerations. The plasma spray equipment was modified to heat, control and monitor the substrate temperature during spraying. Specimens were fabricated and experimentally evaluated to: (1) substantiate the capability of the thermal prestrain method to develop compressive residual stresses in the sprayed structure and (2) define the effect of spraying on a heated substate on abradability, erosion and thermal shock characteristics of the seal system. Thermal stress analysis, including residual stresses and material properties variations, was performed and correlated with thermal shock test results. Seal system performance was assessed and recommendations for further development were made.