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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Measurement and analysis of critical crack tip processes during fatigue crack growth

The mechanics of fatigue crack growth under constant-amplitudes and variable-amplitude loading were examined. Critical loading histories involving relatively simple overload and overload/underload cycles were studied to provide a basic understanding of the underlying physical processes controlling crack growth. The material used for this study was 7091-T7E69, a powder metallurgy aluminum alloy. Local crack-tip parameters were measured at various times before, during, and after the overloads, these include crack-tip opening loads and displacements, and crack-tip strain fields. The latter were useed, in combination with the materials cyclic and monotonic stress-strain properties, to compute crack-tip residual stresses. The experimental results are also compared with analytical predictions obtained using the FAST-2 computer code. The sensitivity of the analytical model to constant-amplitude fatigue crack growth rate properties and to through-thickness constrain are studied.

Davidson, D. L.↗
NASA NTRS1988

Grain boundary oxidation and an analysis of the effects of oxidation on fatigue crack nucleation life

The effects of preoxidation on subsequent fatigue life were studied. Surface oxidation and grain boundary oxidation of a nickel-base superalloy (TAZ-8A) were studied at 600 to 1000 C for 10 to 1000 hours in air. Surface oxides were identified and the kinetics of surface oxidation was discussed. Grain boundary oxide penetration and morphology were studied. Pancake type grain boundary oxide penetrates deeper and its size is larger, therefore, it is more detrimental to fatigue life than cone-type grain boundary oxide. Oxide penetration depth, a (sub m), is related to oxidation temperature, T, and exposure time, t, by an empirical relation of the Arrhenius type. Effects of T and t on statistical variation of a (sub m) were analyzed according to the Weibull distribution function. Once the oxide is cracked, it serves as a fatigue crack nucleus. Statistical variation of the remaining fatigue life, after the formation of an oxide crack of a critical length, is related directly to the statistical variation of grain boundary oxide penetration depth.

Oshida, Y.↗
NASA NTRS1988

Constitutive and life modeling of single crystal blade alloys for root attachment analysis

Work to develop fatigue life prediction and constitutive models for uncoated attachment regions of single crystal gas turbine blades is described. At temperatures relevant to attachment regions, deformation is dominated by slip on crystallographic planes. However, fatigue crack initiation and early crack growth are not always observed to be crystallographic. The influence of natural occurring microporosity will be investigated by testing both hot isostatically pressed and conventionally cast PWA 1480 single crystal specimens. Several differnt specimen configurations and orientations relative to the natural crystal axes are being tested to investigate the influence of notch acuity and the material's anisotropy. Global and slip system stresses in the notched regions were determined from three dimensional stress analyses and will be used to develop fatigue life prediction models consistent with the observed lives and crack characteristics.

Meyer, T. G.↗
NASA NTRSDate not supplied

Analysis of Crack Propagation Transients in Accelerated Fatigue Characterization of Adhesives

The characterization of the rates of crack propagation by means of a Paris law is intended for steady-state fatigue conditions. While rates of crack propagation are primarily driven by 𝐽𝐽𝑚𝑚𝑚𝑚𝑚𝑚, in the presence of evolving process zones and fiber bridging they also depend on the crack propagation length: cracks with fully formed process zones propagate more slowly. Analyses of the rates of crack propagation in laminates secondarily bonded with AF163-2K film adhesive were conducted to identify the rate transients that occur during the formation of the process zone in the adhesive and during the evolution of bridging of the adhesive’s carrier knit across the crack faces. Dávila's CF22 cohesive fatigue damage model was used in finite element analyses of the double cantilever beam test to explain discrepancies in experimental rates of propagation obtained from tests conducted with either increasing or decreasing 𝐽max. The results indicate that the analyses accurately reproduce transient and steady-state rates of propagation observed in the experimental results, as well as the threshold of propagation. Transient rates of propagation always exceed those in steady state, which underscores the need to understand transients and account for them in fatigue characterization. The results also highlight that a Paris curve for steady-state propagation can be obtained most quickly using a decreasing load function, but that this curve consists of an unconservative bound to the rates of propagation. A lateral shift in the Paris curve is proposed for a conservative characterization that removes the effect of bridging and other R-curve effects.

fracture mechanics; delamination; J-integral↗
NASA NTRSDate not supplied

Analysis of Crack Propagation Transients in Accelerated Fatigue Characterization of Adhesives

The characterization of the rates of crack propagation by means of a Paris law is intended for steady-state fatigue conditions. While rates of crack propagation are primarily driven by 𝐽𝐽𝑚𝑚𝑚𝑚𝑚𝑚, in the presence of evolving process zones and fiber bridging they also depend on the crack propagation length: cracks with fully formed process zones propagate more slowly. Analyses of the rates of crack propagation in laminates secondarily bonded with AF163-2K film adhesive were conducted to identify the rate transients that occur during the formation of the process zone in the adhesive and during the evolution of bridging of the adhesive’s carrier knit across the crack faces. Dávila's CF22 cohesive fatigue damage model was used in finite element analyses of the double cantilever beam test to explain discrepancies in experimental rates of propagation obtained from tests conducted with either increasing or decreasing 𝐽max. The results indicate that the analyses accurately reproduce transient and steady-state rates of propagation observed in the experimental results, as well as the threshold of propagation. Transient rates of propagation always exceed those in steady state, which underscores the need to understand transients and account for them in fatigue characterization. The results also highlight that a Paris curve for steady-state propagation can be obtained most quickly using a decreasing load function, but that this curve consists of an unconservative bound to the rates of propagation. A lateral shift in the Paris curve is proposed for a conservative characterization that removes the effect of bridging and other R-curve effects.

fracture mechanics; delamination; J-integral↗
NASA NTRS1991

Preliminary results on the fracture analysis of multi-site cracking of lap joints in aircraft skins

This paper presents results of a fracture mechanics analysis relevant to fatigue crack growth at rivets in lap joints of aircraft skins are presented. Multi-site damage (MSD) is receiving increased attention within the context of problems of aging aircraft. Fracture analyses previously carried out include small-scale modeling of rivet/skin interactions, larger-scale two-dimensional models of lap joints similar to that developed here, and full scale three-dimensional models of large portions of the aircraft fuselage. Fatigue testing efforts have included flat coupon specimens, two-dimensional lap joint tests, and full scale tests on specimens designed to closely duplicate aircraft sections. Most of this work is documented in the proceedings of previous symposia on the aging aircraft problem. The effect MSD has on the ability of skin stiffeners to arrest the growth of long skin cracks is a particularly important topic that remains to be addressed. One of the most striking features of MSD observed in joints of some test sections and in the joints of some of the older aircraft fuselages is the relative uniformity of the fatigue cracks from rivet to rivet along an extended row of rivets. This regularity suggests that nucleation of the cracks must not be overly difficult. Moreover, it indicates that there is some mechanism which keeps longer cracks from running away from shorter ones, or, equivalently, a mechanism for shorter cracks to catch-up with longer cracks. This basic mechanism has not been identified, and one of the objectives of the work is to see to what extent the mechanism is revealed by a fracture analysis of the MSD cracks. Another related aim is to present accurate stress intensity factor variations with crack length which can be used to estimate fatigue crack growth lifetimes once cracks have been initiated. Results are presented which illustrate the influence of load shedding from rivets with long cracks to neighboring rivets with shorter cracks. Results will also be included for the effect of residual stress due to the riveting process itself. All the results presented in this paper should be regarded as preliminary in the sense that further work by ourselves and others will be required to validate them and to establish their sensitivity to more embellished modelling assumptions.

Aging Aircraft↗
NASA NTRS1983

Slow crack growth in spinel in water

Magnesium aluminate spinel was tested in a water environment at room temperature to establish its slow crack-growth behavior. Ring specimens with artificial flaws on the outside surface were loaded hydraulically on the inside surface. The time to failure was measured. Various precracking techniques were evaluated and multiple precracks were used to minimize the scatter in the static fatigue tests. Statistical analysis techniques were developed to determine the strength and crack velocities for a single flaw. Slow crack-growth rupture was observed at stress intensities as low as 70 percent of K sub c. A strengthening effect was observed in specimens that had survived long-time static fatigue tests.

Schwantes, S.↗
DOE OSTI2023

FY23 status report on the development of new ASME Section III, Division 5 Class B rules

This report summarizes the work done in Fiscal Year 2023 on the development of the new American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 5, Class B rules to address the gaps identified for high temperature reactor designs. The summary of the design-by-analysis strain limit evaluation and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. This approach captures the elastic follow-up generated due to interactions of components with adjacent components, supports, and other connections in the power plant. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules, and the experimental data obtained from a family of Simplified Model Test based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1974

Examination of the influence of coatings on thin superalloy sections. Volume 1: Description and analysis

The effects of an aluminide coating and of section thickness were investigated on two cast nickel-base superalloys. Cast section thickness ranged from 0.038 cm to 0.15 cm. Simulated engine exposures in a jet fuel burner rig with cyclic air cooling were studied. The effects of surface machining before coating and re-machining and re-coating after exposures were examined. The properties evaluated included tensile strength, stress rupture, high-cycle mechanical fatigue, and thermal fatigue. A metallurgical analysis was made of the microstructures of the coated and uncoated alloy.

Kaufman, M.↗
DOE OSTI2024

Very high cycle fatigue characteristics of laser beam powder bed fused AlSi10Mg: A systematic evaluation of part geometry

This study explores the influence of geometry and part size on defect distribution, melt pool size, and mechanical characteristics in laser beam powder bed fused (LB-PBF) AlSi10Mg. Five distinct geometries—hourglass, small rod, small block, large block, and large rod—were fabricated under identical process parameters. Fully reversed ultrasonic fatigue testing, operating at a frequency of 20 kHz, was conducted to assess the very high cycle fatigue properties. The findings indicated that part geometry had a major impact on the fatigue properties of the material in the very high cycle fatigue regime. Specimens machined from large rods and large blocks had the lowest porosity and highest fatigue resistance. Microstructural analysis indicated that hourglass, small rod, and small block specimens had shallower melt pools and overlap depths compared to other geometries. This observation suggests a higher cooling rate in specimens with smaller cross-sectional areas, leading to the increased presence of entrapped gas pores and a lack of fusion defects. Understanding the relationship between part geometry and fatigue properties in LB-PBF components offers insights for optimizing design and manufacturing processes in additive manufacturing applications.

AlSi10Mg↗
NASA NTRS1992

Detection and characterization of fatigue cracks in thin metal plates by low frequency resonant model analysis

Low-frequency resonant model analysis, a technique for the detection and characterization of fatigue cracks in thin metal plates, which could be adapted to rapid scan or large area testing, is considered. Experimental data displaying a direct correlation between fatigue crack geometry and resonance frequency for the second vibrational plate mode are presented. FEM is used to calculate the mechanical behavior of the plates, and provides a comparison basis for the experimentally determined resonance frequency values. The waveform of the acoustic emission generated at the resonant frequency is examined; it provides the basis for a model of the interaction of fatigue crack faces during plate vibration.

Wincheski, B.↗
NASA NTRS1974

Fracture control methods for space vehicles. Volume 1: Fracture control design methods

A systematic approach for applying methods for fracture control in the structural components of space vehicles consists of four major steps. The first step is to define the primary load-carrying structural elements and the type of load, environment, and design stress levels acting upon them. The second step is to identify the potential fracture-critical parts by means of a selection logic flow diagram. The third step is to evaluate the safe-life and fail-safe capabilities of the specified part. The last step in the sequence is to apply the control procedures that will prevent damage to the fracture-critical parts. The fracture control methods discussed include fatigue design and analysis methods, methods for preventing crack-like defects, fracture mechanics analysis methods, and nondestructive evaluation methods. An example problem is presented for evaluation of the safe-crack-growth capability of the space shuttle crew compartment skin structure.

Liu, A. F.↗
NASA NTRS1982

Cyclic-inelastic deformation and fatigue resistance of notched-thin aluminum plates

The results of experiments designed to develop data to assess the accuracy and utility of the critical location concept in applications of fatigue-crack nucleation analysis at notch roots are presented and discussed. Fully reversed and nonzero mean-stress data are presented over a range of lives which encompass both elastic and inelastic deformations for thin-notched specimens and smooth specimens made of 2024 T351 aluminum-alloy sheet. Notch-root strains were measured via an extensometer, whereas the formation of small cracks was detected via an eddy-current transducer. Data reported indicated the validity of the assumption that smooth and notched specimens form cracks at the same cycle number when identical deformation histories are imposed at their respective critical locations. They also serve to demonstrate the accuracy and utility of the critical-location approach in analysis to predict the formation of small cracks at notches in coupons and components.

Leis, B. N.↗
NASA NTRS1986

Selection of rolling-element bearing steels for long-life application

Nearly four decades of research in bearing steel metallurgy and processing have resulted in improvements in bearing life by a factor of 100 over that obtained in the early 1940's. For critical applications such as aircraft, these improvements have resulted in longer lived, more reliable commercial aircraft engines. Material factors such as hardness, retained austenite, grain size and carbide size, number, and area can influence rolling-element fatigue life. Bearing steel processing such as double vacuum melting can have a greater efect on bearing life than material chemistry. The selection and specification of a bearing steel is dependent on the integration of all these considerations into the bearing design and application. The paper reviews rolling-element fatigue data and analysis which can enable the engineer or metallurgist to select a rolling-element bearing steel for critical applications where long life is required.

Zaretsky, E. V.↗
NASA NTRS1989

Selection of rolling-element bearing steels for long-life applications

Nearly four decades of research in bearing steel metallurgy and processing have resulted in improvements in bearing life by a factor of 100 over that obtained in the early 1940s. For critical applications such as aircraft, these improvements have resulted in longer lived, more reliable commercial aircraft engines. Material factors such as hardness, retained austenite, grain size and carbide size, number, and area can influence rolling-element fatigue life. Bearing steel processing such as double vacuum melting can have a greater effect on bearing life than material chemistry. The selection and specification of a bearing steel is dependent on the integration of all these considerations into the bearing design and application. The paper reviews rolling-element fatigue data and analysis which can enable the engineer or metallurgist to select a rolling-element bearing steel for critical applications where long life is required.

Zaretsky, Erwin V.↗
NASA NTRS1992

Advanced Rotorcraft Transmission (ART) program summary

The Advanced Rotorcraft Transmission (ART) Program was initiated to advance the state of the art for rotorcraft transmissions. The goal of the ART Program was to develop and demonstrate the technologies needed to reduce transmission weight by 25 pct. and reduce noise by 10 dB while obtaining a 5000 hr 'mean time between failure'. The research done under the ART Program is summarized. A split path design was selected as best able to meet the program goals. Key part technologies needed for this design were identified, studied, and developed. Two of these technologies are discussed in detail: the load sharing of split path designs including the use of a compliant elastomeric torque splitter and the application of a high ratio, low pitch line velocity gear mesh. Development of an angular contact spherical roller bearing, transmission error analysis, and fretting fatigue testing are discussed. The technologies for a light weight, quiet, and reliable rotorcraft transmission were demonstrated.

Krantz, T. L.↗
NASA NTRS1992

Advanced Rotorcraft Transmission (ART) Program summary

The Advanced Rotorcraft Transmission (ART) Program was initiated to advance the state of the art for rotorcraft transmissions. The goal of the ART Program was to develop and demonstrate the technologies needed to reduce transmission weight by 25 pct and reduce noise by 10 dB while obtaining a 5000 hr 'mean time between failure'. The research done under the ART Program is summarized. A split path design was selected as best able to meet the program goals. Key part technologies needed for this design were identified, studied, and developed. Two of these technologies are discussed in detail: the load sharing of split path designs including the use of a compliant elastomeric torque splitter and the application of a high ratio, low pitch line velocity gear mesh. Development of an angular contact spherical roller bearing, transmission error analysis, and fretting fatigue testing are discussed. The technologies for a light weight, quiet, and reliable rotorcraft transmission were demonstrated.

Krantz, T. L.↗