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At least 343 records · Page 19

Three-dimensional finite-element simulation of fatigue crack growth and closure

A three-dimensional elastic-plastic finite-element analysis of crack growth and closure under cyclic loading has been performed in order to investigate the behavior of a crack in a finite-thickness middle-crack tension specimen. The cases of both constant-amplitude loading and a single-spike overload are considered. The calculated crack-opening stresses for the exterior of the specimen agree with previous plane-stress results, and those obtained for the interior of the specimen agree with previous plane-strain results.

Chermahini, R. G.↗

Growth Of Fatigue Cracks In An Aluminum Alloy

Report discusses application of mathematical crack-closure model to study growth of cracks under various load histories. Model based on crack-tip-plasticity concept, modified to leave plastically deformed material in wake of advancing crack tip. Effect of thickness of material on plasticity accounted for by using "constraint" factor in connection with tensile yielding at crack tip.

Newman, J. C., Jr.↗

AVIRIS ground data processing system

During the last year and a half, Feb. 1991 to Jun. 1992, a major upgrade of the Airborne Visible/Infrared Imaging Spectrometers (AVIRIS) ground data processing system took place. Both the hardware and software components were changed significantly to improve the processing capacity and performance and to structure a data facility capable of handling the projected work load into the near future. A summary report of these changes and some projections for the future are provided. The objectives of the AVIRIS data facility are to decommutate and archive AVIRIS data and to provide raw or radiometrically calibrated data products to the science investigator. These primary objectives have not changed from the initial concepts. The upgrade effort has greatly improved the processing system. These objectives can now be accomplished in a more timely fashion at a reasonable cost and there is sufficient capacity to manage the current processing load and provide for future growth. The method of implementation added the flexibility to provide better service to the investigator and allow for future changes.

Hansen, Earl G.↗

Modeling of delamination damage evolution in laminated composites subjected to low velocity impact

This study examines the delamination evolution, under quasi-static conditions, of laminated polymeric composites with mechanically nonlinear resin rich interfaces. The constitutive behavior of the interface is represented by two models developed by Needleman and Tvegaard. These models assumed that the interfacial tractions, a function of only the interfacial displacement, will behave similarly to the interatomic forces generated during the interatomic seperation. The interface material's parameters control the load at which the delamination growth initiates and the final delamination size. A wide range of damage accumulation responses have been obtained by varying the model parameters. These results show that Tvergaard's model has been found to be better suited of the two models in predicting damage evolution for the configurations examined.

Lo, David C.↗

Three-Dimensional Stress Fields and Slip Systems for Single Crystal Superalloy Notched Specimens

Single crystal superalloys have become increasingly popular for turbine blade and vane applications due to their high strength, and creep and fatigue resistance at elevated temperatures. The crystallographic orientation of a single crystal material greatly affects its material properties, including elastic modulus, shear modulus, and ductility. These directional properties, along with the type of loading and temperature, dictate an anisotropic response in the yield strength, creep resistance, creep rupture ductility, fatigue resistance, etc. A significant amount of research has been conducted to determine the material properties in the <001> orientation, yet the material properties deviating from the <001> orientation have not been assessed for all cases. Based on the desired application and design criteria, a crystal orientation is selected to yield the maximum properties. Currently, single crystal manufacturing is able to control the primary crystallographic orientation within 15 of the target orientation, which is an acceptable deviation to meet both performance and cost guidelines; the secondary orientation is rarely specified. A common experiment is the standard load-controlled tensile test, in which specimens with different orientations can be loaded to observe the material response. The deformation behavior of single-crystal materials under tension and compression is known to be a function of not only material orientation, but also of varying microdeformation (i.e. dislocation) mechanisms. The underlying dislocation motion causes deformation via slip, and affects the activation of specific slip systems based on load and orientation. The slip can be analyzed by observing the visible traces left on the surface of the specimen from the slip activity within the single crystal material. The goal of this thesis was to predict the slip systems activated in three-dimensional stress fields of a notched tensile specimen, as a function of crystal orientation, using finite element analysis without addressing microstructural deformation mechanisms that govern their activation. Out of three orientations tested, the specimen with a [110] load orientation and a [001] growth direction had the lowest maximum resolved shear stress; this specimen orientation appears to be the best design candidate for a tensile application.

Magnan, Shannon M.↗

Probabilistic Fracture Mechanics Analysis of the Orbiter's LH2 Feedline Flowliner

Work performed by Southwest Research Institute (SwRI) as part of an Independent Technical Assessment (ITA) for the NASA Engineering and Safety Center (NESC) is summarized. The ITA goal was to establish a flight rationale in light of a history of fatigue cracking due to flow induced vibrations in the feedline flowliners that supply liquid hydrogen to the space shuttle main engines. Prior deterministic analyses using worst-case assumptions predicted failure in a single flight. The current work formulated statistical models for dynamic loading and cryogenic fatigue crack growth properties, instead of using worst-case assumptions. Weight function solutions for bivariant stressing were developed to determine accurate crack "driving-forces". Monte Carlo simulations showed that low flowliner probabilities of failure (POF = 0.001 to 0.0001) are achievable, provided pre-flight inspections for cracks are performed with adequate probability of detection (POD)-specifically, 20/75 mils with 50%/99% POD. Measurements to confirm assumed POD curves are recommended. Since the computed POFs are very sensitive to the cyclic loads/stresses and the analysis of strain gage data revealed inconsistencies with the previous assumption of a single dominant vibrant mode, further work to reconcile this difference is recommended. It is possible that the unaccounted vibrational modes in the flight spectra could increase the computed POFs.

Bonacuse, Peter J.↗

Probabilistic Estimation of Critical Flaw Sizes in the Primary Structure Welds of the Ares I-X Launch Vehicle

The primary structure of the Ares I-X Upper Stage Simulator (USS) launch vehicle is constructed of welded mild steel plates. There is some concern over the possibility of structural failure due to welding flaws. It was considered critical to quantify the impact of uncertainties in residual stress, material porosity, applied loads, and material and crack growth properties on the reliability of the welds during its pre-flight and flight. A criterion--an existing maximum size crack at the weld toe must be smaller than the maximum allowable flaw size--was established to estimate the reliability of the welds. A spectrum of maximum allowable flaw sizes was developed for different possible combinations of all of the above listed variables by performing probabilistic crack growth analyses using the ANSYS finite element analysis code in conjunction with the NASGRO crack growth code. Two alternative methods were used to account for residual stresses: (1) The mean residual stress was assumed to be 41 ksi and a limit was set on the net section flow stress during crack propagation. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if this limit was exceeded during four complete flight cycles, and (2) The mean residual stress was assumed to be 49.6 ksi (the parent material s yield strength) and the net section flow stress limit was ignored. The critical flaw size was determined by parametrically increasing the initial flaw size and detecting if catastrophic crack growth occurred during four complete flight cycles. Both surface-crack models and through-crack models were utilized to characterize cracks in the weld toe.

Pai, Shantaram S.↗

An Overview of Innovative Strategies for Fracture Mechanics at NASA Langley Research Center

Engineering fracture mechanics has played a vital role in the development and certification of virtually every aerospace vehicle that has been developed since the mid-20th century. NASA Langley Research Center s Durability, Damage Tolerance and Reliability Branch has contributed to the development and implementation of many fracture mechanics methods aimed at predicting and characterizing damage in both metallic and composite materials. This paper presents a selection of computational, analytical and experimental strategies that have been developed by the branch for assessing damage growth under monotonic and cyclic loading and for characterizing the damage tolerance of aerospace structures

Ransom, Jonathan B.↗

Repairing Fractured Bones by Use of Bioabsorbable Composites

A proposed method of surgical repair of fractured bones would incorporate recent and future advances in the art of composite materials. The composite materials used in this method would be biocompatible and at least partly bioabsorbable: that is, during the healing process following surgery, they would be wholly or at least partly absorbed into the bones and other tissues in which they were implanted. Relative to the traditional method, the proposed method would involve less surgery, pose less of a risk of infection, provide for better transfer of loads across fracture sites, and thereby promote better healing while reducing the need for immobilization by casts and other external devices. One requirement that both the traditional and proposed methods must satisfy is to fix the multiple segments of a broken bone in the correct relative positions. Mechanical fixing techniques used in the traditional method include the use of plates spanning the fracture site and secured to the bone by screws, serving of wire along the bone across the fracture site, insertion of metallic intramedullary rods through the hollow portion of the fractured bone, and/or inserting transverse rods through the bone, muscle, and skin to stabilize the fractured members. After the bone heals, a second surgical operation is needed to remove the mechanical fixture(s). In the proposed method, there would be no need for a second surgical operation. The proposed method is based partly on the observation that in the fabrication of a structural member, it is generally more efficient and reliable to use multiple small fasteners to transfer load across a joint than to use a single or smaller number of larger fasteners, provided that the stress fields of neighboring small fasteners do not overlap or interact. Also, multiple smaller fasteners are more reliable than are larger and fewer fasteners. However, there is a trade-off between structural efficiency and the cost of insertion time and materials. The proposed method is further based partly on the conjecture that through-the-thickness reinforcements could be excellent for fixing bone segments for surgical repair. The through-the-thickness reinforcements would superficially resemble nails in both form and function. Denoted small-diameter rods (SDRs) to distinguish them from other narrow rods, these reinforcements would be shot or otherwise inserted through adjacent segments of fractured bone to fix them in their correct relative positions (see figure). Shot insertion would be effected by use an applicator that would amount to a miniaturized and highly refined version of the pneumatic guns often used in carpentry to drive nails and brads. The applicator, envisioned to be about the size of a ball-point-pen, would be driven by pressurized carbon dioxide. To further promote stabilization of the segments, layers of bone glue could be applied to the fracture surfaces prior to insertion of the SDRs. The bone glue could be therapeutically loaded with chemicals to promote growth of bone and fight infection

Farley, Gary L.↗

Fracture Analysis of Semi-Elliptical Surface Cracks in Ductile Materials

Accurate life assessment of structural components may require advanced life prediction criteria and methodologies. Structural components often exhibit several different types of defects, among the most prevalent being surface cracks. A semi-elliptical surface crack subjected to monotonic loading will exhibit stable crack growth until the crack has reached a critical size, at which the crack loses stability and fracture ensues (Newman, 2000). The shape and geometry of the flaw are among the most influential factors. When considering simpler crack configurations, such as a through-the-thickness crack, a three-dimensional (3D) geometry may be modeled under the approximation of two-dimensional (2D) plane stress or plane strain. The more complex surface crack is typically modeled numerically with the Finite Element Method (FEM). A semi-elliptical surface crack is illustrated in Figure 1-1.

Daniewicz, S. R.↗

The effect of water vapor on fatigue crack Growth in 7475-t651 aluminum alloy plate

The effects of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate at frequencies of 1 Hz and 10 Hz were investigated. Twenty-five mm thick compact specimens were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Fatigue crack growth rates were calculated from effective crack lengths determined using a compliance method. Tests were conducted in hard vacuum and at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. Fatigue crack growth rates were frequency insensitive under all environment conditions tested. For constant stress intensity factor ranges crack growth rate transitions occurred at low and high water vapor pressures. Crack growth rates at intermediate pressures were relatively constant and showed reasonable agreement with published data for two Al-Cu-Mg alloys. The existence of two crack growth rate transitions suggests either a change in rate controlling kinetics or a change in corrosion fatigue mechanism as a function of water vapor pressure. Reduced residual deformation and transverse cracking specimens tested in water vapor versus vacuum may be evidence of embrittlement within the plastic zone due to environmental interaction.

Dicus, D. L.↗

Effect of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate

The effects of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate at frequencies of 1 Hz and 10 Hz were investigated. Twenty-five mm thick compact specimens were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Fatigue crack growth rates were calculated from effective crack lengths determined using a compliance method. Tests were conducted in hard vacuum and at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. Fatigue crack growth rates were frequency insensitive under all environment conditions tested. For constant stress intensity factor ranges crack growth rate transitions occurred at low and high water vapor pressures. Crack growth rates at intermediate pressures were relatively constant and showed reasonable agreement with published data for two Al-Cu-Mg alloys. The existence of two crack growth rate transitions suggests either a change in rate controlling kinetics or a change in corrosion fatigue mechanism as a function of water vapor pressure. Reduced residual deformation and transverse cracking specimens tested in water vapor versus vacuum may be evidence of embrittlement within the plastic zone due to environmental interaction.

Dicus, D. L.↗

Predicting the growth of small and large cracks using a crack-closure model

An evaluation is conducted of the ability of a crack-closure model to predict the fatigue life of notched specimens under spectrum loading, for the cases of crack initiation and growth along the bore of a semicircular notch and the growth of large cracks in 2024-T3 Al alloy sheets under constant-amplitude loading. These cases are used to establish an initial defect size and relationship between the stress-intensity factor range and crack-growth rate. Experimental and calculation results for small-crack growth rates are in good agreement and exhibited a stress level effect at equal values of stress-intensity factor range.

Newman, J. C., Jr.↗

Computational Methods for Frictional Contact With Applications to the Space Shuttle Orbiter Nose-Gear Tire

A computational procedure is presented for the solution of frictional contact problems for aircraft tires. A Space Shuttle nose-gear tire is modeled using a two-dimensional laminated anisotropic shell theory which includes the effects of variations in material and geometric parameters, transverse-shear deformation, and geometric nonlinearities. Contact conditions are incorporated into the formulation by using a perturbed Lagrangian approach with the fundamental unknowns consisting of the stress resultants, the generalized displacements, and the Lagrange multipliers associated with both contact and friction conditions. The contact-friction algorithm is based on a modified Coulomb friction law. A modified two-field, mixed-variational principle is used to obtain elemental arrays. This modification consists of augmenting the functional of that principle by two terms: the Lagrange multiplier vector associated with normal and tangential node contact-load intensities and a regularization term that is quadratic in the Lagrange multiplier vector. These capabilities and computational features are incorporated into an in-house computer code. Experimental measurements were taken to define the response of the Space Shuttle nose-gear tire to inflation-pressure loads and to inflation-pressure loads combined with normal static loads against a rigid flat plate. These experimental results describe the meridional growth of the tire cross section caused by inflation loading, the static load-deflection characteristics of the tire, the geometry of the tire footprint under static loading conditions, and the normal and tangential load-intensity distributions in the tire footprint for the various static vertical loading conditions. Numerical results were obtained for the Space Shuttle nose-gear tire subjected to inflation pressure loads and combined inflation pressure and contact loads against a rigid flat plate. The experimental measurements and the numerical results are compared.

Tanner, John A.↗

Computational methods for frictional contact with applications to the Space Shuttle orbiter nose-gear tire: Comparisons of experimental measurements and analytical predictions

A computational procedure is presented for the solution of frictional contact problems for aircraft tires. A Space Shuttle nose-gear tire is modeled using a two-dimensional laminated anisotropic shell theory which includes the effects of variations in material and geometric parameters, transverse-shear deformation, and geometric nonlinearities. Contact conditions are incorporated into the formulation by using a perturbed Lagrangian approach with the fundamental unknowns consisting of the stress resultants, the generalized displacements, and the Lagrange multipliers associated with both contact and friction conditions. The contact-friction algorithm is based on a modified Coulomb friction law. A modified two-field, mixed-variational principle is used to obtain elemental arrays. This modification consists of augmenting the functional of that principle by two terms: the Lagrange multiplier vector associated with normal and tangential node contact-load intensities and a regularization term that is quadratic in the Lagrange multiplier vector. These capabilities and computational features are incorporated into an in-house computer code. Experimental measurements were taken to define the response of the Space Shuttle nose-gear tire to inflation-pressure loads and to inflation-pressure loads combined with normal static loads against a rigid flat plate. These experimental results describe the meridional growth of the tire cross section caused by inflation loading, the static load-deflection characteristics of the tire, the geometry of the tire footprint under static loading conditions, and the normal and tangential load-intensity distributions in the tire footprint for the various static vertical-loading conditions. Numerical results were obtained for the Space Shuttle nose-gear tire subjected to inflation pressure loads and combined inflation pressure and contact loads against a rigid flat plate. The experimental measurements and the numerical results are compared.

Tanner, John A.↗

An assessment of the small-crack effect for 2024-T3 aluminum alloy

Data on small-crack behavior were obtained for a single-edge-notched tensile specimen made of 2024-T3 Al alloy and used to evaluate the capability of a semiempirical crack-growth and closure model to predict the fatigue life of notched specimens. Fatigue tests were conducted under either constant-amplitude loading (with stress ratios of 0.5, 0, -1, and -2) or spectrum loading, using a replication technique to record growth. It was found that small cracks exhibited the 'small-crack' effect in that they grew faster than large cracks when subjected to the same stress intensity factor range. Experimental small-crack growth rates agreed well with the model predictions. For making predictions of fatigue life, an initial surface defect void size of 3 x 12 x 0.4 microns was used in all calculations; predicted fatigue lives agreed well with experimentally determined values obtained in all tests. The crack-closure model indicated that the 'small-crack' effect on fatigue life was greatest in tests involving significant compressive loads.

Newman, J. C., Jr.↗

Anomolous Fatigue Crack Growth Phenomena in High-Strength Steel

The growth of a fatigue crack through a material is the result of a complex interaction between the applied loading, component geometry, three-dimensional constraint, load history, environment, material microstructure and several other factors. Previous studies have developed experimental and computational methods to relate the fatigue crack growth rate to many of the above conditions, with the intent of discovering some fundamental material response, i.e. crack growth rate as a function of something. Currently, the technical community uses the stress intensity factor solution as a simplistic means to relate fatigue crack growth rate to loading, geometry and all other variables. The stress intensity factor solution is a very simple linear-elastic representation of the continuum mechanics portion of crack growth. In this paper, the authors present fatigue crack growth rate data for two different high strength steel alloys generated using standard methods. The steels exhibit behaviour that appears unexplainable, compared to an aluminium alloy presented as a baseline for comparison, using the stress intensity factor solution.

Forth, Scott C.↗