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NASA NTRS1988

Hot corrosion of ceramic engine materials

A number of commercially available SiC and Si3N4 materials were exposed to 1000 C in a high velocity, pressurized burner rig as a simulation of a turbine engine environment. Sodium impurities added to the burner flame resulted in molten Na2SO4 deposition, attack of the SiC and Si4N4 and formation of substantial Na2O-x(SiO2) corrosion product. Room temperature strength of the materials decreased. This was a result of the formation of corrosion pits in SiC, and grain boundary dissolution and pitting in Si3N4. Corrosion regimes for such Si-based ceramics have been predicted using thermodynamics and verified in rig tests of SiO2 coupons. Protective mullite coatings are being investigated as a solution to the corrosion problem for SiC and Si3N4. Limited corrosion occurred to cordierite (Mg2Al4Si5O18) but some cracking of the substrate occurred.

Fox, Dennis S.↗

NASA NTRS1976

MSFC crack growth analysis computer program, version 2 (users manual)

An updated version of the George C. Marshall Space Flight Center Crack Growth Analysis Program is described. The updated computer program has significantly expanded capabilities over the original one. This increased capability includes an extensive expansion of the library of stress intensity factors, plotting capability, increased design iteration capability, and the capability of performing proof test logic analysis. The technical approaches used within the computer program are presented, and the input and output formats and options are described. Details of the stress intensity equations, example data, and example problems are presented.

Creager, M.↗

NASA NTRS1992

Oxidation of Al2O3 continuous fiber-reinforced/NiAl composites

The 1200 C and 1300 C isothermal and cyclic oxidation behavior of Al2O3 continuous fiber-reinforced/NiAl composites were studied. Oxidation resulted in formation of Al2O3 external scales in a similar manner as scales formed on monolithic NiAl. The isothermal oxidation of an Al2O3/NiAl composite resulted in oxidation of the matrix along the fiber/matrix interface near the fiber ends. This oxide acted as a wedge between the fiber and the matrix, and, under cyclic oxidation conditions, led to further oxidation along the fiber lengths and eventual cracking of the composite. The oxidation behavior of composites in which the Al2O3 fibers were sputter coated with nickel prior to processing was much more severe. This was attributed to open channels around the fibers which formed during processing, most likely as a result of the diffusion of the nickel coating into the matrix.

Doychak, J.↗

NASA NTRS1994

Origin of the hydrocarbon component of interplanetary dust particles

Using experiments as a basis, we have developed a scenario for the origin of the hydrocarbon material of carbonaceous chondrites. This scenario can also serve as an explanation for the origin of the hydrocarbon component of interplanetary dust particles (IDP's). The formation of polycyclic aromatic hydrocarbon (PAH) molecules in the atmospheres of C stars undergoing a late stage of stellar evolution is indicated by the observed unidentified infrared (UIR) emission bands. Those molecules are then transported through interstellar space where they become enriched with D through ion molecule reactions when passing through cold, dark clouds. Many of those PAH molecules are subsequently hydrogenated and cracked in a H-dominated plasma such as would have occurred in the solar nebula. The resulting mixture of alkanes and residual D-rich PAH molecules was then incorporated into the mineral fraction of the parent bodies of carbonaceous chondrites and IDP's.

Wdowiak, Thomas J.↗

NASA NTRS1994

Collection, processing, and reporting of damage tolerant design data for non-aerospace structural materials

This report describes the organization, format and content of the NASA Johnson damage tolerant database which was created to store damage tolerant property data for non aerospace structural materials. The database is designed to store fracture toughness data (K(sub IC), K(sub c), J(sub IC) and CTOD(sub IC)), resistance curve data (K(sub R) VS. delta a (sub eff) and JR VS. delta a (sub eff)), as well as subcritical crack growth data (a vs. N and da/dN vs. delta K). The database contains complementary material property data for both stainless and alloy steels, as well as for aluminum, nickel, and titanium alloys which were not incorporated into the Damage Tolerant Design Handbook database.

Huber, P. D.↗

NASA NTRS1991

Statistics of contractive cracking patterns

The statistics of convective soil patterns are analyzed using statistical crystallography. An underlying hierarchy of order is found to span four orders of magnitude in characteristic pattern length. Strict mathematical requirements determine the two-dimensional (2D) topology, such that random partitioning of space yields a predictable statistical geometry for polygons. For all lengths, Aboav's and Lewis's laws are verified; this result is consistent both with the need to fill 2D space and most significantly with energy carried not by the patterns' interior, but by the boundaries. Together, this suggests a common mechanism of formation for both micro- and macro-freezing patterns.

Noever, David A.↗

NASA NTRS1975

Assessment of NDE reliability data

Twenty sets of relevant nondestructive test (NDT) reliability data were identified, collected, compiled, and categorized. A criterion for the selection of data for statistical analysis considerations was formulated, and a model to grade the quality and validity of the data sets was developed. Data input formats, which record the pertinent parameters of the defect/specimen and inspection procedures, were formulated for each NDE method. A comprehensive computer program was written and debugged to calculate the probability of flaw detection at several confidence limits by the binomial distribution. This program also selects the desired data sets for pooling and tests the statistical pooling criteria before calculating the composite detection reliability. An example of the calculated reliability of crack detection in bolt holes by an automatic eddy current method is presented.

Yee, B. G. W.↗

NASA NTRS1985

Fault Offsets and Lateral Crustal Movement on Europa

Structural evidence is presented for tension cracking associated with strike slip faulting and crustal movement in the bright ice covered Galilean satellite Europa. The structure and morphology of wedge shaped bands argues that they formed as a result of the rotation and lateral displacement of crustal units bounded by near vertical faults penetrating through the brittle crustal layer. The significant rotation and lateral motion of crustal blocks near the anti-jove point on Europa, without graben formation, also argues that the lithosphere in the fractured area is mechanically decoupled from the solid silicate interior, by either warm ice at depth or liquid water. Ice at depth and at a large fraction of its melting temperature is expected to behave as a fluid over geologically short time intervals due to its extremely low viscosity relative to the cold, brittle ice near the surface. One proposed convection mechanism is thus considered unlikely as it would be difficult to transmit internal stress through a decoupling layer to the surface.

Schenk, P. M.↗

NASA NTRS1990

Magnetic particle inspection

The purpose of this experiment is to familiarize the student with magnetic particle inspection and relate it to classification of various defects. Magnetic particle inspection is a method of detecting the presence of cracks, laps, tears, inclusions, and similar discontinuities in ferromagnetic materials such as iron and steel. This method will most clearly show defects that are perpendicular to the magnetic field. The Magnaglo method uses a liquid which is sprayed on the workpiece to be inspected, and the part is magnetized at the same time. The workpiece is then viewed under a black light, and the presence of discontinuity is shown by the formation of a bright indication formed by the magnetic particles over the discontinuity. The equipment and experimental procedures are described.

Sastri, Sankar↗

NASA NTRS2019

A Long-Term Vision for Space-Based Interferometry

The processes leading to the formation of planets; the extreme physics occurring near the event horizon of black holes; detailed studies of exoplanets through spectral-spatial mapping: new and unique insights into the physical processes involved across nearly the whole gamut of astrophysics await discovery at small angular scales. The fine spatial resolution needed to explore these processes, however, lies beyond the capabilities of current astronomical facilities and nearly all proposed future facilities. Interferometers can crack this angular resolution problem, and space-based interferometry missions promise to explore entirely new regions of scientific phase space, providing unique new insights into the physical processes lurking at small angular scales.

Rinehart, S. A.↗

NASA NTRS2019

LCF Life of As-Deposited and Annealed NiCr-Y Coatings for Oxidation and Hot Corrosion Protection of Disk Alloys

Increasing temperatures in aero gas turbines is resulting in oxidation and hot corrosion attack of turbine disks. Since disks are sensitive to low cycle fatigue (LCF), any environmental attack, and especially hot corrosion pitting, can seriously degrade the life of the disk. Application of metallic coatings is one means of protecting disk alloys from this environmental attack. However, the presence of a metallic coating can degrade the LCF life of a disk alloy. Therefore, coatings must be designed which are not only resistant to oxidation and corrosion attack, but do not significantly degrade the LCF life of the alloy.Three different NiCr-Y coating compositions (29, 35.5, 44 wt.% Cr, all with 0.1 wt.% Y) were applied at two thicknesses by Plasma Enhanced Magnetron Sputtering (PEMS) to two similar Ni-based disk alloys. One Ni-35.5Cr-0.1Y coating also received a thin ZrO2 overcoat. The coated samples were also given a short thermal anneal in a low PO2 environment to encourage bonding of the coating and substrate as well as initiating formation of a chromia scale. Without further environmental exposure, the LCF life of coated and uncoated samples was evaluated at 760Â°C in air. The LCF lifetime of all coated samples was less than that of uncoated samples. The LCF life scaled with the Cr content and the high-Cr, thin coating showed the highest LCF life. Pre and post-test characterization of the various coatings, including identification of crack initiation sites, will be presented and the effect of the coating on the LCF life discussed.

low cycle fatigue↗

NASA NTRS1987

Surface flaw reliability analysis of ceramic components with the SCARE finite element postprocessor program

The SCARE (Structural Ceramics Analysis and Reliability Evaluation) computer program on statistical fast fracture reliability analysis with quadratic elements for volume distributed imperfections is enhanced to include the use of linear finite elements and the capability of designing against concurrent surface flaw induced ceramic component failure. The SCARE code is presently coupled as a postprocessor to the MSC/NASTRAN general purpose, finite element analysis program. The improved version now includes the Weibull and Batdorf statistical failure theories for both surface and volume flaw based reliability analysis. The program uses the two-parameter Weibull fracture strength cumulative failure probability distribution model with the principle of independent action for poly-axial stress states, and Batdorf's shear-sensitive as well as shear-insensitive statistical theories. The shear-sensitive surface crack configurations include the Griffith crack and Griffith notch geometries, using the total critical coplanar strain energy release rate criterion to predict mixed-mode fracture. Weibull material parameters based on both surface and volume flaw induced fracture can also be calculated from modulus of rupture bar tests, using the least squares method with known specimen geometry and grouped fracture data. The statistical fast fracture theories for surface flaw induced failure, along with selected input and output formats and options, are summarized. An example problem to demonstrate various features of the program is included.

Gyekenyesi, John P.↗

NASA NTRS1987

Surface flaw reliability analysis of ceramic components with the SCARE finite element postprocessor program

Gyekenyesi, J. P.↗

NASA NTRS1994

Scaling of impact damage in fiber composites

Impact damage in fiber composite structures remains of much concern, and is often the limiting factor in establishing allowable strain levels. The complexity of impact damage formation usually dictates that experiments are required, but scaling of results from small laboratory scale specimens to large structures introduces additional uncertainty into the analysis. This presentation gives the results of an analytical and experimental investigation intended to develop procedures for prediction of damage formation and subsequent strength loss, with particular emphasis on scaling of results with respect to structure size. The experimental investigation involved both drop-weight and airgun impact on carbon/epoxy plates and cylinders. Five sizes of plates ranging from 50 by 50 by 1.072 mm to 250 by 250 by 5.36 mm, and two sizes of cylinders with diameters of 96.5 and 319 mm, were employed in the experimental program. Impact tests were carried out over a range of impact conditions, and specimens were inspected for damage by C-scan and deplying. Analysis procedures were developed for both quasistatic and dynamic impacts for both the plates and cylinders. As has been reported previously, comparison of predicted structural response and measured surface strains was quite good over the entire range of sizes employed in the program. The damage formation and strength loss after impact showed a number of interesting features that are significant with respect to scaling of size. The extent of delamination was observed to increase with specimen size more than would be expected if stresses controlled the delamination extent. This was explained on the basis that delamination is controlled by energy release rates, and thus incorporates the usual dependence on the absolute size characteristic of fracture mechanics. Additionally, the experiments indicated that delamination initiated at matrix cracks and is dependent on the absolute size of the ply group thicknesses. Both the initiation and propagation of delamination are seen to be controlled by fracture mechanics parameters, and thus show specific dependence on size that must be accounted for in extrapolating results from laboratory scale tests to full size structures.

Swanson, Stephen R.↗

NASA NTRS2007

A New Sea Ice Model: Pancakes to Metrics

We are developing, testing, and validating a new sea ice dynamics model that treats the ice cover as an elastic/decohesive material in the permanent pack and includes the correct frazil/pancake behavior in the marginal zone. Two salient features of present ice dynamics models are that they do not: 1) reproduce the oriented fracture patterns of openings and closings in the pack ice, and 2) accurately model the effects of frazil/pancake ice formation in the ice margin. These poorly modeled areas account for a substantial portion of the ice growth, turbulent heat flux to the atmosphere, salt flux to the ocean, and energy dissipation due to slippage, ridging, and rafting, in the Arctic. Existing sea ice models have shown limited success in predicting the degree to which a lead will open for prescribed or observed forcing conditions. An important aspect of the new model we are developing is that the existence of cracks, along with their orientation, opening, and closing, is predicted. To put this effort in perspective a short history of ice dynamics modeling and data collection is presented. The RGPS data set is used to validate the model. As part of the testing and validation of the model, we are working on a new metric for comparing linear features (leads and ridges) in the data and model to be used in data assimilation for this model. The model framework is presented as well as some results showing the creation and development of leads in a simulation of ice dynamics in the Beaufort Sea. Other presentations by the authors will show other results from this effort.

Coon, M.↗

NASA NTRS1989

Aging effects on the fracture toughness of SiC whisker reinforced 2XXX aluminum alloys

The effect of aging (at 150 C) time on the fracture toughness behavior of a 2XXX alloy (Al-3.55Cu-1.29Mg-0.01Fe-trace Mn) reinforced with 5 vol pct F-8 SiC whiskers was investigated by measuring hardness and electrical conductivity followed by fracture toughness tests on center-cracked specimens. The ageing time-hardening response plots showed that, independent of whisker orientation, the initial rapid increase in hardness was followed by a more gradual increase, with a broad hardness peak between 32 and 128 hrs of aging. Coincident with the hardness changes, the electrical conductivity initially decreased, reached a minimum, and then increased at aging times beyond 32 hrs. Examination by SEM indicated that the initial increase in hardness and decrease in conductivity was due to the GPB zone formation, while the subsequent increase in electrical conductivity and decrease in hardness (overaging) was due to S nucleation and growth.

Ratnaparkhi, P. L.↗

NASA NTRS1998

WARP3D-Release 10.8: Dynamic Nonlinear Analysis of Solids using a Preconditioned Conjugate Gradient Software Architecture

This report describes theoretical background material and commands necessary to use the WARP3D finite element code. WARP3D is under continuing development as a research code for the solution of very large-scale, 3-D solid models subjected to static and dynamic loads. Specific features in the code oriented toward the investigation of ductile fracture in metals include a robust finite strain formulation, a general J-integral computation facility (with inertia, face loading), an element extinction facility to model crack growth, nonlinear material models including viscoplastic effects, and the Gurson-Tver-gaard dilatant plasticity model for void growth. The nonlinear, dynamic equilibrium equations are solved using an incremental-iterative, implicit formulation with full Newton iterations to eliminate residual nodal forces. The history integration of the nonlinear equations of motion is accomplished with Newmarks Beta method. A central feature of WARP3D involves the use of a linear-preconditioned conjugate gradient (LPCG) solver implemented in an element-by-element format to replace a conventional direct linear equation solver. This software architecture dramatically reduces both the memory requirements and CPU time for very large, nonlinear solid models since formation of the assembled (dynamic) stiffness matrix is avoided. Analyses thus exhibit the numerical stability for large time (load) steps provided by the implicit formulation coupled with the low memory requirements characteristic of an explicit code. In addition to the much lower memory requirements of the LPCG solver, the CPU time required for solution of the linear equations during each Newton iteration is generally one-half or less of the CPU time required for a traditional direct solver. All other computational aspects of the code (element stiffnesses, element strains, stress updating, element internal forces) are implemented in the element-by- element, blocked architecture. This greatly improves vectorization of the code on uni-processor hardware and enables straightforward parallel-vector processing of element blocks on multi-processor hardware.

Koppenhoefer, Kyle C.↗

NASA NTRS1995

Durability of Silica-Protected Ceramics in Combustion Atmospheres

This overview of oxidation and corrosion effects on silica-protected ceramics and composites is divided into two parts: (1) External effects and (2) Internal effects. In regard to the first part, the literature indicates silica the best of the common protective oxides in pure oxygen. However in actual applications, there are four major degradation routes which must be considered: (1) Formation of SiO(g); (2) water vapor enhancement of oxidation rate of Si(OH)4 volatiles; (3) low level metal cation enhancement of oxidation rate; and (4) molten salt and slag corrosion. Several protective coating concepts have been discussed, which may minimize these effects. Internal effects deal with a microcrack providing a path for oxygen ingress to the oxygen sensitive fiber and fiber coating. This is a critical area of study for theses materials. Possible solutions involve a fluid glass to fill the cracks and/or oxygen getting along the walls of the crack.

Jacobson, Nathan S.↗