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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Failure of Laminated Composites at Thickness Discontinuities: An Experimental and Analytical Study

Failure initiation of laminated composites at a thickness discontinuity is studied experimentally with the aid of an optical microscope under combined loading of tension, transverse shear and bending, making use of three- and four-point bending arrangements. Because transverse shear produced relatively small effects in failure initiation results are presented as tension-bending interactions. Two loading frames for three- and four-point bending were designed to apply moment and tension simultaneously to produce failure by generating a ply crack; this initiation was evaluated by finite element analysis using ABAQUS. For cross-plies bounding the interface at the base of the step it is found that a maximum strain criterion applied to the continuing (long) ply describes the failure initiation. Ultimate failure resulted at loads on the order of 25 to 35% higher than those at failure initiation.

Lee, Sangwook↗
NASA NTRS2016

Dynamic Characterization of Galfenol (Fe81.6Ga18.4)

Galfenol has the potential to transform the smart materials industry by allowing for the development of multifunctional, load-bearing devices. One of the primary technical challenges faced by this development is the very limited experimental data on Galfenol's frequency-dependent response to dynamic stress, which is critically important for the design of such devices. This report details a novel and precise characterization of the constitutive behavior of polycrystalline Galfenol (Fe81.6Ga18.4) under quasi-static (1 Hz) and dynamic (4 to 1000 Hz) stress loadings. Mechanical loads are applied using a high-frequency load frame. Quasi-static minor and major hysteresis loop measurements of magnetic flux density and strain are presented for constant electromagnet currents (0 to 1.1 A) and constant magnetic fields 0 to 14 kA/m (0 to 180 Oe). The dynamic stress amplitude for minor and major loops is 2.88 and 31.4 MPa (418 and 4550 psi), respectively. Quasi-static material properties closely match published values for similar Galfenol materials. Quasi-static actuation responses are also measured and compared to quasi-static sensing responses; the high degree of reversibility seen in the comparison is consistent with published measurements and modeling results. Dynamic major and minor loops are measured for dynamic stresses up to 31 MPa (4496 psi) and 1 kHz, and the bias condition resulting in maximum, quasi-static sensitivity. Eddy current effects are quantified by considering solid and laminated Galfenol rods. Three key sources of error in the dynamic measurements are accounted for: (1) electromagnetic noise in strain signals due to Galfenol's magnetic response, (2) error in load signals due to the inertial force of fixturing, and (3) phase misalignment between signals due to conditioning electronics. For dynamic characterization, strain error is kept below 1.2 percent of full scale by wiring two collocated gauges in series (noise cancellation) and through leadwire weaving. Inertial force error is kept below 0.41 percent by measuring the dynamic force in the specimen using a nearly collocated piezoelectric load washer. The phase response of all conditioning electronics is explicitly measured and corrected for. In general, as frequency is increased, the sensing response becomes more linear because of an increase in eddy currents. As frequency increases above approximately 100 Hz, the elbow in the strain-versus-stress response disappears as the active (soft) regime stiffens toward the passive (hard) regime. Under constant-field conditions, the loss factors of the solid rod peak between 200 and 600 Hz, rather than exhibiting a monotonic increase. Compared to the solid rod, the laminated rod exhibits much slower increases in hysteresis with frequency, and its quasi-static behavior extends to higher frequencies. The elastic modulus of the laminated rod decreases between 100 and 300 Hz; this trend is currently unexplained.

Dynamic sensing↗
NASA NTRS1990

Ultrasonic Monitor To Determine Crack-Opening Load

New ultrasonic monitor to determine crack-opening load in compact tension specimen uses transducers to pass acoustic wave across crack region. Definite improvement in signal-to-noise ratio. Process possesses substantial immunity from noise caused by operation of load frame and associated parts. In addition to applications for aerospace community, this monitor and concept clearly have general utility in testing of materials and potentially in nondestructive evaluation of solid parts.

Yost, William T.↗
NASA NTRS1990

Simulated rotor test apparatus dynamic characteristics in the 80- by 120-foot wind tunnel

A shake test was conducted in the 80 by 120 foot Wind Tunnel at NASA Ames Research Center, using a load frame and dummy weights to simulate the weight of the NASA Rotor Test Apparatus. The simulated hub was excited with broadband random excitation, and accelerometer responses were measured at various locations. The transfer functions (acceleration per unit excitation force as a function of frequency) for each of the accelerometer responses were computed, and the data were analyzed using modal analysis to estimate the model parameters.

Hoque, M. S.↗
NASA NTRS1991

A low cost method of testing compression-after-impact strength of composite laminates

A method was devised to test the compression strength of composite laminate specimens that are much thinner and wider than other tests require. The specimen can be up to 7.62 cm (3 in) wide and as thin as 1.02 mm (.04 in). The best features of the Illinois Institute of Technology Research Institute (IITRI) fixture are combined with an antibuckling jig developed and used at the University of Dayton Research Institute to obtain a method of compression testing thin, wide test coupons on any 20 kip (or larger) loading frame. Up to 83 pct. less composite material is needed for the test coupons compared to the most commonly used compression-after-impact (CAI) tests, which calls for 48 ply thick (approx. 6.12 mm) test coupons. Another advantage of the new method is that composite coupons of the exact lay-up and thickness of production parts can be tested for CAI strength, thus yielding more meaningful results. This new method was used to compression test 8 and 16 ply laminates of T300/934 carbon/epoxy. These results were compared to those obtained using ASTM standard D 3410-87 (Celanese compression test). CAI testing was performed on IM6/3501-6, IM7/SP500 and IM7/F3900. The new test method and associated fixture work well and is a valuable asset to MSFC's damage tolerance program.

Nettles, Alan T.↗
NASA NTRS1991

Compression-after-impact testing of thin composite materials

A new method has been devised to test composite specimens as thin as 8 plies and up to 7.6 cm in width for compression strength. This method utilizes a fixture incorporating the best features of the Celanese and IITRI fixtures combined with an antibuckling jig developed at the University of Dayton Research Institute. This new method uses up to 83 percent less material than the most commonly used compression-after-impact technique (which calls for a 48 ply test specimen) and can also be performed on smaller loading frames since a much smaller force is needed to fail the specimen. The thickness of the test specimen can be fabricated to exactly match production part thickness, thus yielding more meaningful results. CAI tests were performed on IM6/3501 carbon/epoxy utilizing this new method. To verify the design, a series of tests were performed in which undamaged specimens were tested using the new fixture and ASTM D 3410-87 (Celanese compression test) and the results compared. The new fixture works well and will be a valuable asset to MSFC's damage tolerance program.

Nettles, Alan T.↗
NASA NTRS1994

In Situ Radiography During Tensile Tests

Laboratory system for testing specimens of metal-, ceramic-, and intermetallic-matrix composite materials incorporates both electromechanical tensile-testing subsystem and either of two imaging subsystems that take x-ray photographs of specimens before, during, and after tensile tests. Used to test specimens of reaction-bonded silicon nitride reinforced with silicon carbide fibers (SiC/RBSN) considered for high-temperature service in advanced aircraft turbine engines. Provides data on effects of preexisting flaws (e.g., high-density impurities and local variations of density) on fracture behavior. Accumulated internal damage monitored during loading. X-ray source illuminates specimen in load frame while specimen is pulled. X-ray images on film correlated with stress-vs.-strain data from tensile test.

Baaklini, George Y.↗
NASA NTRS1994

Fatigue-Crack-Tip Locator

Fatigue-testing system includes automated subsystem continuously tracking location of fatigue-crack tip in metal or other highly electrically conductive specimen. Fatigue-crack-tip-locating subsystem also searches specimen to find initial fatigue crack and its tip and to trace out hidden fatigue cracks and other flaws inside specimen. Subsystem operates under overall control of personal computer, which also controls load frame applying prescribed cyclic stresses to specimen. Electromagnetic flaw detector based on eddy-current principle scanned over surface of specimen. Flaw detector described in "Electromagnetic Flaw Detector Is Easier To Use" (LAR-15046). System provides automated control and monitoring of fatigue experiments, saving time for researchers and enabling experiments to run unattended 24 hours a day. All information on crack-tip trajectories and rates of growth of cracks recorded automatically, so researchers have access to more information.

Namkung, Min↗
NASA NTRS1996

Determination of Elastic Moduli of Fiber-Resin Composites Using an Impulse Excitation Technique

The elastic moduli of graphite/epoxy and graphite/cyanate ester composite specimens with various laminate lay-ups was determined using an impulse excitation/acoustic resonance technique and compared to those determined using traditional strain gauge and extensometer techniques. The stiffness results were also compared to those predicted from laminate theory using uniaxial properties. The specimen stiffnesses interrogated ranged from 12 to 30 Msi. The impulse excitation technique was found to be a relatively quick and accurate method for determining elastic moduli with minimal specimen preparation and no requirement for mechanical loading frames. The results of this investigation showed good correlation between the elastic modulus determined using the impulse excitation technique, strain gauge and extensometer techniques, and modulus predicted from laminate theory. The flexural stiffness determined using the impulse excitation was in good agreement with that predicted from laminate theory. The impulse excitation/acoustic resonance interrogation technique has potential as a quality control test.

Viens, Michael J.↗
NASA NTRS2005

Prediction of Fretting Crack Location and Orientation in a Single Crystal Nickel Alloy

Fretting is a structural damage mechanism arising between two nominally clamped surfaces subjected to an oscillatory loading. A critical location for fretting induced damage has been identified at the blade/disk and blade/damper interfaces of gas turbine engine turbomachinery and space propulsion components. The high- temperature, high-frequency loading environment seen by these components lead to severe stress gradients at the edge-of-contact that could potentially foster crack growth leading to component failure. These contact stresses drive crack nucleation in fretting and are very sensitive to the geometry of the contacting bodies, the contact loads, materials, temperature, and contact surface tribology (friction). Recently, a high-frequency, high-temperature load frame has been designed for experimentally investigating fretting damage of single crystal nickel materials employed in aircraft and spacecraft turbomachinery. A modeling method for characterizing the fretting stresses of the spherical fretting contact stress behavior in this experiment is developed and described. The calculated fretting stresses for a series of experiments are then correlated to the observed fretting damage. Results show that knowledge of the normal stresses and resolved shear stresses on each crystal plane can aid in predicting crack locations and orientations.

Matlik, J. F.↗
NASA NTRS2004

Characterization of Composite Fan Case Resins

The majority of commercial turbine engines that power today s aircraft use a large fan driven by the engine core to generate thrust which dramatically increases the engine s efficiency. However, if one of these fan blades fails during flight, it becomes high energy shrapnel, potentially impacting the engine or puncturing the aircraft itself and thus risking the lives of passengers. To solve this problem, the fan case must be capable of containing a fan blade should it break off during flight. Currently, all commercial fan cases are made of either just a thick metal barrier or a thinner metal wall surrounded by Kevlar-an ultra strong fiber that elastically catches the blade. My summer 2004 project was to characterize the resins for a composite fan case that will be lighter and more efficient than the current metal. The composite fan case is created by braiding carbon fibers and injecting a polymer resin into the braid. The resin holds the fibers together, so at first using the strongest polymer appears to logically lead to the strongest fan case. Unfortunately, the stronger polymers are too viscous when melted. This makes the manufacturing process more difficult because the polymer does not flow as freely through the braid, and the final product is less dense. With all of this in mind, it is important to remember that the strength of the polymer is still imperative; the case must still contain blades with high impact energy. The research identified which polymer had the right balance of properties, including ease of fabrication, toughness, and ability to transfer the load to the carbon fibers. Resin deformation was studied to better understand the composite response during high speed impact. My role in this research was the testing of polymers using dynamic mechanical analysis and tensile, compression, and torsion testing. Dynamic mechanical analysis examines the response of materials under cyclic loading. Two techniques were used for dynamic mechanical analysis. The ARES Instrument analyzed the material through torsion. The second machine, TA Instruments apparatus, applied a bending force to the specimen. These experiments were used to explore the effects of temperature and strain rate on the stiffness and strength of the resins. The two different types of loading allowed us to verify our results. An axial-torsional load frame, manufactured by MTS Systems, Inc., was used to conduct the tensile, compression, and torsional testing. These tests were used to determine the stress-strain curves for the resins. The elastic and plastic deformation data was provided to another team member for characterization of high fidelity material property predictions. This information was useful in having a better understanding of the polymers so that the fan cases could be as sturdy as possible. Deformation studies are the foundation for the computational modeling that provides the structural design of a composite engine case as well as detailed analysis of the blade impact event.

Dvoracek, Charlene M.↗
NASA NTRS2000

Strain Measurement System Developed for Biaxially Loaded Cruciform Specimens

A new extensometer system developed at the NASA Glenn Research Center at Lewis Field measures test area strains along two orthogonal axes in flat cruciform specimens. This system incorporates standard axial contact extensometers to provide a cost-effective high-precision instrument. The device was validated for use by extensive testing of a stainless steel specimen, with specimen temperatures ranging from room temperature to 1100 F. In-plane loading conditions included several static biaxial load ratios, plus cyclic loadings of various waveform shapes, frequencies, magnitudes, and durations. The extensometer system measurements were compared with strain gauge data at room temperature and with calculated strain values for elevated-temperature measurements. All testing was performed in house in Glenn's Benchmark Test Facility in-plane biaxial load frame.

Krause, David L.↗
NASA NTRS2015

Design and Testing of a Dynamically-Tuned Magnetostrictive Spring with Electrically-Controlled Stiffness

This paper details the development of an electrically-controlled, variable-stiffness spring based on magnetostrictive materials. The device, termed a magnetostrictive Varispring, can be applied as a semi-active vibration isolator or switched stiffness vibration controller for reducing transmitted vibrations. The Varispring is designed using 1D linear models that consider the coupled electrical response, mechanically-induced magnetic diffusion, and the effect of internal mass on dynamic stiffness. Modeling results illustrate that a Terfenol-D-based Varispring has a rise time almost an order of magnitude smaller and a magnetic diffusion cut-off frequency over two orders of magnitude greater than a Galfenol-based Varispring. The results motivate the use of laminated Terfenol-D rods for a greater stiffness tuning range and increased bandwidth. The behavior of a prototype Varispring is examined under vibratory excitation up to 6 MPa and 25 Hz using a dynamic load frame. For this prototype, stiffness is indirectly varied by controlling the excitation current. Preliminary measurements of continuous stiffness tuning via sinusoidal currents up to 1 kHz are presented. The measurements demonstrate that the Young's modulus of the Terfenol-D rod inside the Varispring can be continuously varied by up to 21.9 GPa. The observed stiffness tuning range is relatively constant up to 500 Hz, but significantly decreases thereafter. The stiffness tuning range can be greatly increased by improving the current and force control such that a more consistent current can be applied and the Varispring can be accurately tested at a more optimal bias stress.

Vibration control↗
NASA NTRS2016

Experimental Comparison of Piezoelectric and Magnetostrictive Shunt Dampers

A novel mechanism called the vibration ring is being developed to enable energy conversion elements to be incorporated into the driveline of a helicopter or other rotating machines. Unwanted vibration is transduced into electrical energy, which provides a damping effect on the driveline. The generated electrical energy may also be used to power other devices (e.g., health monitoring sensors). PZT (piezoceramic) and PMN-30PT (single crystal) stacks, as well as a Tb_0.3 Dy_0.7 Fe_1.92 (Terfenol-D) rod with a bias magnet array and a pickup coil, were tested as alternative energy conversion elements to use within the vibration ring. They were tuned for broadband damping using shunt resistors, and dynamic compression testing was conducted in a high-speed load frame. Energy conversion was experimentally optimized at 750Hz by tuning the applied bias stress and resistance values. Dynamic testing was conducted up to 1000Hz to determine the effective compressive modulus, shunt loss factor, internal loss factor, and total loss factor. Some of the trends of modulus and internal loss factor versus frequency were unexplained. The single crystal device exhibited the greatest shunt loss factor whereas the Terfenol-D device had the highest internal and total loss factors. Simulations revealed that internal losses in the Terfenol-D device were elevated by eddy current effects, and an improved magnetic circuit could enhance its shunt damping capabilities. Alternatively, the Terfenol-D device may be simplified to utilize only the eddy current dissipation mechanism (no pickup coil or shunt) to create broadband damping.

energy conversion↗
NASA NTRS2016

Experimental Comparison of Piezoelectric and Magnetostrictive Shunt Dampers

A novel mechanism called the vibration ring is being developed to enable energy conversion elements to be incorporated into the driveline of a helicopter or other rotating machines. Unwanted vibration is transduced into electrical energy, which provides a damping effect on the driveline. The generated electrical energy may also be used to power other devices (e.g., health monitoring sensors). PZT (piezoceramic) and PMN-30%PT (single crystal) stacks, as well as a Tb_0.3 Dy_0.7 Fe_1.92 (Terfenol-D) rod with a bias magnet array and a pickup coil, were tested as alternative energy conversion elements to use within the vibration ring. They were tuned for broadband damping using shunt resistors, and dynamic compression testing was conducted in a high-speed load frame. Energy conversion was experimentally optimized at 750Hz by tuning the applied bias stress and resistance values. Dynamic testing was conducted up to 1000Hz to determine the effective compressive modulus, shunt loss factor, internal loss factor, and total loss factor. Some of the trends of modulus and internal loss factor versus frequency were unexplained. The single crystal device exhibited the greatest shunt loss factor whereas the Terfenol-D device had the highest internal and total loss factors. Simulations revealed that internal losses in the Terfenol-D device were elevated by eddy current effects, and an improved magnetic circuit could enhance its shunt damping capabilities. Alternatively, the Terfenol-D device may be simplified to utilize only the eddy current dissipation mechanism (no pickup coil or shunt) to create broadband damping.

piezoelectric↗
NASA NTRS1939

Loads imposed on intermediate frames of stiffened shells

The loads imposed on intermediate frames by the curvature of the longitudinal and by the diagonal-tension effects are treated. A new empirical method is proposed for analyzing diagonal-tension effects. The basic formulas of the pure diagonal-tension theory are used, and the part of the total shear S carried by diagonal tension is assumed to be given the expression S (sub DT) = S (1-tau sub o/tau)(sup n) where tau (sub o) is the critical shear stress, tau the total (nominal shear stress), and n = 3 - sigma/tau where sigma is the stress in the intermediate frame. Numerical examples illustrate all cases treated.

STRESSED SKIN↗
NASA NTRS2011

Sources of Variation in Creep Testing

Creep rupture is an important material characteristic for the design of rocket engines. It was observed during the characterization of GRCop-84 that the complete data set had nearly 4 orders of magnitude of scatter. This scatter likely confounded attempts to determine how creep performance was influenced by manufacturing. It was unclear if this variation was from the testing, the material, or both. Sources of variation were examined by conducting tests on identically processed specimens at the same specified stresses and temperatures. Significant differences existed between the five constant-load creep frames. The specimen temperature was higher than the desired temperature by as much as 43 C. It was also observed that the temperature gradient was up to 44 C. Improved specimen temperature control minimized temperature variations. The data from additional tests demonstrated that the results from all five frames were comparable. The variation decreased to 1/2 order of magnitude from 2 orders of magnitude for the baseline data set. Independent determination of creep rates in a reference load frame closely matched the creep rates determined after the modifications. Testing in helium tended to decrease the sample temperature gradient, but helium was not a significant improvement over vacuum.

Loewenthal, William S.↗
NASA NTRS1987

Impact response of composite fuselage frames

Graphite-epoxy frames were drop tested onto a concrete floor to simulate crash loadings. The frames have Z-shaped cross sections typical of designs often proposed for fuselage structure of advanced composite transports. A diameter of six feet for the frames was chosen to reduce specimen fabrication costs and to facilitate testing. Accelerometer, strain gage, and photographic measurements are presented which characterize the impact behavior of frames with differing masses to represent structural or seat/occupant masses. Failures of the graphite-epoxy frames involved complete separations through the cross section. All damage to the lightly loaded composite frames was confined to an area close to the impact point. Subsequent failures left and right of the impact point occurred for the more heavily loaded specimens.

Boitnott, Richard L.↗