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At least 37 records · Page 2

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NASA NTRS1994

Evaluation of the fuselage lap joint fatigue and terminating action repair

Terminating action is a remedial repair which entails the replacement of shear head countersunk rivets with universal head rivets which have a larger shank diameter. The procedure was developed to eliminate the risk of widespread fatigue damage (WFD) in the upper rivet row of a fuselage lap joint. A test and evaluation program has been conducted by Foster-Miller, Inc. (FMI) to evaluate the terminating action repair of the upper rivet row of a commercial aircraft fuselage lap splice. Two full scale fatigue tests were conducted on fuselage panels using the growth of fatigue cracks in the lap joint. The second test was performed to evaluate the effectiveness of the terminating action repair. In both tests, cyclic pressurization loading was applied to the panels while crack propagation was recorded at all rivet locations at regular intervals to generate detailed data on conditions of fatigue crack initiation, ligament link-up, and fuselage fracture. This program demonstrated that the terminating action repair substantially increases the fatigue life of a fuselage panel structure and effectively eliminates the occurrence of cracking in the upper rivet row of the lap joint. While high cycle crack growth was recorded in the middle rivet row during the second test, failure was not imminent when the test was terminated after cycling to well beyond the service life. The program also demonstrated that the initiation, propagation, and linkup of WFD in full-scale fuselage structures can be simulated and quantitatively studied in the laboratory. This paper presents an overview of the testing program and provides a detailed discussion of the data analysis and results. Crack distribution and propagation rates and directions as well as frequency of cracking are presented for both tests. The progression of damage to linkup of adjacent cracks and to eventual overall panel failure is discussed. In addition, an assessment of the effectiveness of the terminating action repair and the occurrence of cracking in the middle rivet row is provided, and conclusions of practical interest are drawn.

Samavedam, Gopal↗

NASA NTRS1999

A Single-Lap Joint Adhesive Bonding Optimization Method Using Gradient and Genetic Algorithms

A natural process for any engineer, scientist, educator, etc. is to seek the most efficient method for accomplishing a given task. In the case of structural design, an area that has a significant impact on the structural efficiency is joint design. Unless the structure is machined from a solid block of material, the individual components which compose the overall structure must be joined together. The method for joining a structure varies depending on the applied loads, material, assembly and disassembly requirements, service life, environment, etc. Using both metallic and fiber reinforced plastic materials limits the user to two methods or a combination of these methods for joining the components into one structure. The first is mechanical fastening and the second is adhesive bonding. Mechanical fastening is by far the most popular joining technique; however, in terms of structural efficiency, adhesive bonding provides a superior joint since the load is distributed uniformly across the joint. The purpose of this paper is to develop a method for optimizing single-lap joint adhesive bonded structures using both gradient and genetic algorithms and comparing the solution process for each method. The goal of the single-lap joint optimization is to find the most efficient structure that meets the imposed requirements while still remaining as lightweight, economical, and reliable as possible. For the single-lap joint, an optimum joint is determined by minimizing the weight of the overall joint based on constraints from adhesive strengths as well as empirically derived rules. The analytical solution of the sin-le-lap joint is determined using the classical Goland-Reissner technique for case 2 type adhesive joints. Joint weight minimization is achieved using a commercially available routine, Design Optimization Tool (DOT), for the gradient solution while an author developed method is used for the genetic algorithm solution. Results illustrate the critical design variables as a function of adhesive properties and convergences of different joints based on the two optimization methods.

Smeltzer, Stanley S., III↗

DOE OSTI2019

High-Speed Friction stir lap welding of Al alloys

Friction stir lap welding (FSLW) with linear speed of 1m/min or higher can open up opportunities for industrial implementation of FSLW. This paper will provide an overview of several challenges and mitigation strategies to produce effective joints between several Al alloys. FSLW of Al alloys at high speed presents challenges including interface hook features and defects at the interface. Combination of 5xxx, 6xxx and 7xxx Al alloys were joined and characterized. Load bearing capacity in excess of 80% of base material strength has been demonstrated at the welding speed of 2m/min for 6xxx and 5xxx similar lap joints. The effects of parameters like welding speed, RPM, tool geometry in material flow features, void volume, and hook geometry is investigated and this knowledge base is applied to improve the joint strength of 7xxx series lap welds.

Upadhyay, Piyush↗

DOE OSTI2018

Reducing Intermetallic Compounds of Mg/Al Joint in Friction Stir Lap Welding

To reduce intermetallic compounds (IMCs) of Al{sub 12}Mg{sub 17} and Al{sub 3}Mg{sub 2} in Mg/Al friction stir lap welding joint, pin tip was plunged into the lower sheet at a small distance. Results showed that at a fixed welding speed of 50 mm/min, sound joints were obtained using rotating speeds from 750 to 500 rpm, and the IMCs zones were rather small. Cracks easily appeared inside IMCs inside onion ring and at lap interface. Therefore, reducing the IMC was beneficial for reducing the crack. Joint lap shear stress firstly increased and then decreased with decrease in the rotating speed. The maximum shear stress of 50.2 MPa was attained at a rotating speed of 500 rpm because of reduced IMC.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Review on failure prediction techniques of composite single lap joint

Adhesive bonding is the most appropriate joining method in construction of composite structures. The use of reliable design and prediction technique will produce better performance of bonded joints. Several papers from recent papers and journals have been reviewed and synthesized to understand the current state of the art in this area. It is done by studying the most relevant analytical solutions for composite adherends with start of reviewing the most fundamental ones involving beam/plate theory. It is then extended to review single lap joint non linearity and failure prediction and finally on the failure prediction on composite single lap joint. The review also encompasses the finite element modelling part as tool to predict the elastic response of composite single lap joint and failure prediction numerically.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2018

Mechanical Characterization Study of Sintered Silver Pastes Bonded in a Double-Lap Configuration

Sintered silver-based bonded interfaces are a critical enabling technology for high-temperature, compact, high-performance, and reliable wide-bandgap packages and components. High-pressure (~40 MPa) sintered silver interfaces have been implemented commercially, most notably the commercial products offered by Semikron. To reduce manufacturing complexity, there is significant industry interest in pressure-less sintered silver interfaces. To this end, current formulations of sintered silver paste are comprised of purely nano-sized silver particles or a combination of nano- and micro-sized silver particles/flakes. It is essential to quantify the mechanical properties and determine the reliability of these interfaces prior to use in automotive power electronics applications. In this paper, research efforts at the National Renewable Energy Laboratory, in collaboration with Virginia Polytechnic Institute and State University and an industry partner, in optimizing the synthesis procedure and mechanical characterization of sintered silver double-lap samples are described. These double-lap samples were synthesized using pressure-less sintering techniques. Shear testing was conducted at multiple temperatures and displacement rates on these samples sintered using two types of sintered sintered silver pastes, one of them consisting of nano-silver particles and the other a hybrid paste or a combination of nano- and micron-sized silver flakes, employed in a double-lap configuration. Maximum values of shear stress obtained from the characterization study are reported.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2016

Coordinated analysis of two graphite grains from the CO3.0 LAP 031117 meteorite: first identification of a CO nova graphite and a presolar iron sulfide subgrain

Presolar grains constitute the remnants of stars that existed before the formation of the solar system. In addition to providing direct information on the materials from which the solar system formed, these grains provide ground-truth information for models of stellar evolution and nucleosynthesis. Here we report the in situ identification of two unique presolar graphite grains from the primitive meteorite LaPaz Icefield 031117. Based on these two graphite grains, we estimate a bulk presolar graphite abundance of 5{sub −3}{sup +7} ppm in this meteorite. One of the grains (LAP-141) is characterized by an enrichment in {sup 12}C and depletions in {sup 33,34}S, and contains a small iron sulfide subgrain, representing the first unambiguous identification of presolar iron sulfide. The other grain (LAP-149) is extremely {sup 13}C-rich and {sup 15}N-poor, with one of the lowest {sup 12}C/{sup 13}C ratios observed among presolar grains. Comparison of its isotopic compositions with new stellar nucleosynthesis and dust condensation models indicates an origin in the ejecta of a low-mass CO nova. Grain LAP-149 is the first putative nova grain that quantitatively best matches nova model predictions, providing the first strong evidence for graphite condensation in nova ejecta. Our discovery confirms that CO nova graphite and presolar iron sulfide contributed to the original building blocks of the solar system.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS1984

Effect of preforming adherends on static and fatigue strength of bonded composite single-lap joints

An analytical and experimental investigation was conducted on bonded composite single-lap joints with the adherends performed to reduce the angle between the line of action of the applied in-plane force and the bondline. A classical closed-form solution was used to analyze the composite joints with various preform angles and overlap lengths. The adherends of the test specimens were preformed before bonding, during the layup and curing process. Static tests were conducted for preform angles of 0, 5, 10, and 15 deg and overlap lengths of 0.75, 1.75, 2.75, and 3.75 in. A limited fatigue study was conducted for specimens with a 2.75-in. overlap and a preform angle of 5 deg. Results of the analysis showed that preforming the adherends of bonded composite single-lap joints significantly reduced the shear and peel stress concentrations in the adhesive. Experimental results showed that preforming the adherends significantly increased their static and fatigue strength and thus increased the load level for which bonded composite single-lap joints can be designed.

Sawyer, J. W.↗

NASA NTRS1988

Large-scale Advanced Prop-fan (LAP) technology assessment report

The technologically significant findings and accomplishments of the Large Scale Advanced Prop-Fan (LAP) program in the areas of aerodynamics, aeroelasticity, acoustics and materials and fabrication are described. The extent to which the program goals related to these disciplines were achieved is discussed, and recommendations for additional research are presented. The LAP program consisted of the design, manufacture and testing of a near full-scale Prop-Fan or advanced turboprop capable of operating efficiently at speeds to Mach .8. An aeroelastically scaled model of the LAP was also designed and fabricated. The goal of the program was to acquire data on Prop-Fan performance that would indicate the technology readiness of Prop-Fans for practical applications in commercial and military aviation.

Degeorge, C. L.↗

NASA NTRS1987

Large-scale Advanced Prop-fan (LAP) static rotor test report

Discussed is Static Rotor Testing of the SR-7L Large Scale Advanced Prop-Fan (LAP). The LAP is an advanced 9 foot diameter, 8 bladed propeller designed and built by Hamilton Standard under contract to the NASA Lewis Research Center. The Prop-Fan employs thin swept blades to provide efficient propulsion at flight speeds up to Mach .85. Static Testing was conducted on a 10,000 HP whirl rig at Wright Patterson Air Force Base. The test objectives were to investigate the Prop-Fan static aerodynamic and structural dynamic performance, determine the blade steady state stressers and deflections and to measure steady and unsteady pressures on the SR-7L blade surface. The measured performance of the LAP correlated well with analytical predictions at blade pitch angles below 30 deg. A stall buffet phenomenon was observed at blade pitch angles above 30 deg. This phenomenon manifested itself by elevated blade vibratory stress levels and lower than expected thrust produced and power absorbed by the Prop-Fan for a given speed and blade angle.

Degeorge, Charles L.↗

NASA NTRS1991

Measurements of fuselage skin strains and displacements near a longitudinal lap joint in a pressurized aircraft

Strains and displacements in a small area near a longitudinal lap joint in the fuselage skin of a B737 aircraft were measured during a pressurization cycle to a differential pressure of 6.2 psi while the aircraft was on the ground. It was found that hoop strains were higher than longitudinal strains at each location; membrane strains in the unreinforced skin were higher than in the joint; membrane strains in the hoop direction, as well as radial displacements, tended to be highest at the mid-bay location between skin reinforcements; significant bending in the hoop direction occurred in the joint and in the skin near the joint, and the bending was unsymmetrically distributed about the stringer at the middle of the joint; and radial displacements were unsymmetrically distributed across the lap joint. The interpretation of the strain gage data for locations on the bonded and riveted lap joint assumed that the joint did not contain disbonded areas.

Phillips, Edward P.↗

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 NTRS1998

Methodology for Predicting the Onset of Widespread Fatigue Damage in Lap-Splice Joints

NASA has conducted an Airframe Structural Integrity Program to develop the methodology to predict the onset of widespread fatigue damage to lap-splice joints of fuselage structures. Several stress analysis codes have been developed or enhanced to analyze the lap-splice-joint configuration. Fatigue lives in lap-splice-joint specimens and fatigue-crack growth in a structural fatigue test article agreed well with calculations from small-crack theory and fatigue-crack growth analyses with the FASTRAN code. Residual-strength analyses of laboratory specimens and wide stiffened panels were predicted quite well from the critical crack-tip-opening angle (CTOA) fracture criterion and elastic-plastic finite-element analyses (two- or three-dimensional codes and the STAGS shell code).

Newman, J. C., Jr.↗

NASA NTRS2000

Residual Strength Analyses of Riveted Lap-Splice Joints

The objective of this paper was to analyze the crack-linkup behavior in riveted-stiffened lap-splice joint panels with small multiple-site damage (MSD) cracks at several adjacent rivet holes. Analyses are based on the STAGS (STructural Analysis of General Shells) code with the critical crack-tip-opening angle (CTOA) fracture criterion. To account for high constraint around a crack front, the "plane strain core" option in STAGS was used. The importance of modeling rivet flexibility with fastener elements that accurately model load transfer across the joint is discussed. Fastener holes are not modeled but rivet connectivity is accounted for by attaching rivets to the sheet on one side of the cracks that simulated both the rivet diameter and MSD cracks. Residual strength analyses made on 2024-T3 alloy (1.6-mm thick) riveted-lap-splice joints with a lead crack and various size MSD cracks were compared with test data from Boeing Airplane Company. Analyses were conducted for both restrained and unrestrained buckling conditions. Comparison of results from these analyses and results from lap-splice-joint test panels, which were partially restrained against buckling indicate that the test results were bounded by the failure loads predicted by the analyses with restrained and unrestrained conditions.

Seshadri, B. R.↗

NASA NTRS2004

Petrography of Lunar Meteorite LAP 02205, a New Low-Ti Basalt Possibly Launch Paired with NWA 032

Lunar meteorite LAP 02205 is a 1.23 kg basalt collected during the 2002 field season in the La- Paz ice field, Antarctica [1]. We present a petrographic description including mineral modes and compositions, and the major-element composition of the bulk meteorite. LAP 02205 is an Fe-rich, moderately low-Ti mare basalt that is similar in composition, mineralogy, and mineral chemistry to the NWA 032 basaltic lunar meteorite. LAP 02205 is yet another of the moderately low- Ti basaltic meteorites that are underrepresented among Apollo and Luna samples but that appear from remote sensing to be the most common basalt type on the Moon.

Jolliff, B. L.↗

NASA NTRS2004

Global-Local Finite Element Analysis of Bonded Single-Lap Joints

Adhesively bonded lap joints involve dissimilar material junctions and sharp changes in geometry, possibly leading to premature failure. Although the finite element method is well suited to model the bonded lap joints, traditional finite elements are incapable of correctly resolving the stress state at junctions of dissimilar materials because of the unbounded nature of the stresses. In order to facilitate the use of bonded lap joints in future structures, this study presents a finite element technique utilizing a global (special) element coupled with traditional elements. The global element includes the singular behavior at the junction of dissimilar materials with or without traction-free surfaces.

Kilic, Bahattin↗

NASA NTRS2012

Nonlinear Analysis of Bonded Composite Tubular Lap Joints

The present study describes a semi-analytical solution method for predicting the geometrically nonlinear response of a bonded composite tubular single-lap joint subjected to general loading conditions. The transverse shear and normal stresses in the adhesive as well as membrane stress resultants and bending moments in the adherends are determined using this method. The method utilizes the principle of virtual work in conjunction with nonlinear thin-shell theory to model the adherends and a cylindrical shear lag model to represent the kinematics of the thin adhesive layer between the adherends. The kinematic boundary conditions are imposed by employing the Lagrange multiplier method. In the solution procedure, the displacement components for the tubular joint are approximated in terms of non-periodic and periodic B-Spline functions in the longitudinal and circumferential directions, respectively. The approach presented herein represents a rapid-solution alternative to the finite element method. The solution method was validated by comparison against a previously considered tubular single-lap joint. The steep variation of both peeling and shearing stresses near the adhesive edges was successfully captured. The applicability of the present method was also demonstrated by considering tubular bonded lap-joints subjected to pure bending and torsion.

E. Oterkus↗

DOE OSTI2023

Microstructure and texture evolution of friction stir lap welded dissimilar multi-aluminum stack

Here this work investigates the microstructural evolution of a dissimilar multiple-aluminum alloy stack (AA7055, AA7055, AA6022) produced by friction stir lap welding (FSLW). A through-thickness analyses of grain orientation map, grain size and distribution, strain distribution, and texture evolution by electron backscattered diffraction-based characterization technique were performed. Two different welding parameters (combination of tool rotation and traverse speed) were used to study the effects of the welding parameters on these microstructural characteristics. The study shows that higher welding speed and higher rotation speed of the FSLW tool yield finer grains. FSLW resulted in shear texture formation in the weld regions due to high welding speeds. This texture development in the nugget zone is consistent with shear deformation, and (111) pole figures show ideal shear texture components. The Stir Zone (SZ) exhibits shear texture (A/A ̅ and B/B ̅ components), consistent with other shear-assisted processes. Recrystallization mechanisms observed are CDRX in SZ and DDRX in TMAZ (Thermo-Mechanically Affected Zone). Interface analysis reveals the presence of oxide layers between different aluminum sheets, affecting joint mechanical performance. The mechanical property of the lap welded joints was presented in terms of microhardness distribution across the weld cross section. Slightly higher hardness in higher speed welding setup was observed throughout the SZ and AA6022 layer, indicating greater grain refinement and uniform grain structure distribution.

36 MATERIALS SCIENCE↗