On the dynamic plastic response of finite bars.
Dynamic plastic response of finite bar subject to axial impact load noting reflected waves, stress- strain-time histories and residual strain
Liu, T. H.↗
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Dynamic plastic response of finite bars
Dynamic plastic response of finite bar subject to axial impact load noting reflected waves, stress- strain-time histories and residual strain
Liu, T. H.↗
Luminescent Tension-Indicating Orthopedic Strain Gauges for Non-Invasive Measurements Through Tissue
Strain gauges that can provide information with regard to the state of implantable devices are described. The strain gauges can exhibit luminescence that is detectable through living tissue, and the detectable luminescent emission can vary according to the strain applied to the gauge. A change in residual strain of the device can signify a loss of mechanical integrity and/or loosening of the implant, and this can be non-invasively detected either by simple visual detection of the luminescent emission or through examination of the emission with a detector such as a spectrometer or a camera.
Anker, Jeffrey↗
A Universal Threshold for the Assessment of Load and Output Residuals of Strain-Gage Balance Data
A new universal residual threshold for the detection of load and gage output residual outliers of wind tunnel strain{gage balance data was developed. The threshold works with both the Iterative and Non{Iterative Methods that are used in the aerospace testing community to analyze and process balance data. It also supports all known load and gage output formats that are traditionally used to describe balance data. The threshold's definition is based on an empirical electrical constant. First, the constant is used to construct a threshold for the assessment of gage output residuals. Then, the related threshold for the assessment of load residuals is obtained by multiplying the empirical electrical constant with the sum of the absolute values of all first partial derivatives of a given load component. The empirical constant equals 2.5 microV/V for the assessment of balance calibration or check load data residuals. A value of 0.5 microV/V is recommended for the evaluation of repeat point residuals because, by design, the calculation of these residuals removes errors that are associated with the regression analysis of the data itself. Data from a calibration of a six-component force balance is used to illustrate the application of the new threshold definitions to real{world balance calibration data.
wind tunnel balance↗
Lamination residual stresses in hybrid composites, part 1
An experimental investigation was conducted to study lamination residual stresses for various material and loading parameters. The effects of hybridization on residual stresses and residual properties after thermal cycling under load were determined in angle-ply graphite/Kevlar/epoxy and graphite/S-glass/epoxy laminates. Residual strains in the graphite plies are not appreciably affected by the type and number of hybridizing plies. Computed residual stresses at room temperature in the S-glass plies reach values up to seventy-five percent of the transverse strength of the material. Computed residual stresses in the graphite plies exceed the static strength by approximately ten percent. In the case of Kevlar plies, computed residual stresses far exceed the static strength indicating possible early failure of these plies. Static testing of the hybrids above indicates that failure is governed by the ultimate strain of the graphite plies. In thermally cycled hybrids, in general, residual moduli were somewhat lower and residual strengths were higher than initial values.
Daniel, I. M.↗
A Novel Microcharacterization Technique in the Measurement of Strain and Orientation Gradient in Advanced Materials
Representation of morphology and evolution of the microstructure during processing and their relation to properties requires proper experimental techniques. Residual strains, lattice distortion, and texture (micro-texture) at the interface and the matrix of a layered structure or a functionally gradient material and their variation are among parameters important in materials characterization but hard to measure with present experimental techniques. Current techniques available to measure changes in interred material parameters (residual stress, micro-texture, microplasticity) produce results which are either qualitative or unreliable. This problem becomes even more complicated in the case of a temperature variation. These parameters affect many of the mechanical properties of advanced materials including stress-strain relation, ductility, creep, and fatigue. A review of some novel experimental techniques using recent advances in electron microscopy is presented here to measure internal stress, (micro)texture, interracial strength and (sub)grain formation and realignment. Two of these techniques are combined in the chamber of an Environmental Scanning Electron Microscope to measure strain and orientation gradients in advanced materials. These techniques which include Backscattered Kikuchi Diffractometry (BKD) and Microscopic Strain Field Analysis are used to characterize metallic and intermetallic matrix composites and superplastic materials. These techniques are compared with the more conventional x-ray diffraction and indentation techniques.
Garmestai, H.↗
Residual stresses in angleplied laminates and their effects on laminate behavior
Evidence of the presence of lamination residual stresses in angleplied laminates were transply cracks and warpage of unsymmetric laminates which occur prior to application of any mechanical load. Lamination residual strains were measured using the embedded strain gage technique. These strains result from the temperature differences between cure and room temperature and vary linearly within this temperature range. Lamination residual stresses were usually present in angleplied fiber composites laminates; they were also present in unidirectional hybrids and superhybrids. For specific applications, the magnitudes of lamination residual stresses were determined and evaluated relative to the anticipated applied stresses. Particular attention was given to cyclic thermal loadings in applications where the thermal cycling takes place over a wide temperature range.
Chamis, C. C.↗
Measurement of Plastic Stress and Strain for Analytical Method Verification (MSFC Center Director's Discretionary Fund Project No. 93-08)
The analytical prediction of stress, strain, and fatigue life at locations experiencing local plasticity is full of uncertainties. Much of this uncertainty arises from the material models and their use in the numerical techniques used to solve plasticity problems. Experimental measurements of actual plastic strains would allow the validity of these models and solutions to be tested. This memorandum describes how experimental plastic residual strain measurements were used to verify the results of a thermally induced plastic fatigue failure analysis of a space shuttle main engine fuel pump component.
Price, J. M.↗
Large Wire Strain Gauges
Wires yield data on average strains over distances ranging from inches to many feet. Long constantan wires used to measure average strains over distances characteristic of vehicles or buildings. Connected in bridge circuit, wires measure strain accurately within 1 percent, and linearly, within 0.1 percent. Wires stretch as much as 0.15 percent and still return to zero residual strain after release.
Bryner, B. D.↗
Exploring the Role of Type-II Residual Stresses in A Laser Powder Bed Fusion Nickel-Based Superalloy Using Measurement and Modeling
Far-field high-energy X-ray diffraction microscopy (ff-HEDM) and the crystal plasticity finite element method (CPFEM) are used to investigate the role of grain-scale (Type-II) residual stresses on the fatigue life of additively manufactured (AM) Inconel alloy 625 (IN-625). Grain-averaged orientations, centroids, and residual elastic strain tensors from ff-HEDM data are used to instantiate a crystal plasticity model to simulate the effect of residual stresses at the grain scale. Simulation results indicate that the presence of tensile residual strains increase stress localization and heterogeneity within grains, triggering an earlier onset of plasticity. A microscale fatigue indicator parameter (FIP) is computed to model the impact of these residual strains on the cycles to fatigue crack nucleation. The crack nucleation model, based on the computed FIPs, predicts a significant reduction in the number of cycles for fatigue crack nucleation for mid- and high-cycle fatigue due to the residual strain induced localization, while the residual strains have minimal impact on low-cycle fatigue life.
Inconel↗
Residual thermal stresses in composites for dimensionally stable spacecraft applications
An overview of NASA LaRC's research on thermal residual stresses and their effect on the dimensional stability of carbon fiber reinforced polymer-matrix composites is presented. The data show that thermal residual stresses can induce damage in polymer matrix composites and significantly affect the dimensional stability of these composites by causing permanent residual strains and changes in CTE. The magnitude of these stresses is primarily controlled by the laminate configuration and the applied temperature change. The damage caused by thermal residual stresses initiates at the fiber/matrix interface and micromechanics level analyses are needed to accurately predict it. An increased understanding of fiber/matrix interface interactions appears to be the best approach for improving a composite's resistance to thermally induced damage.
Bowles, David E.↗
Residual stress measurement in silicon sheet by shadow moire interferometry
A shadow moire interferometry technique has been developed to measure residual strain in thin silicon sheet. The curvature of a segment of sheet undergoing four-point bending is analyzed to include the applied bending moments, the in-plane residual stresses, and the 'end effect' of the sheet since it is of finite length. The technique is applied to obtain residual stress distributions for silicon sheet grown by the edge-defined film-fed growth technique.
Kwon, Y.↗
Optical fiber sensors for damage analysis in aerospace materials
Under this grant, fiber optic sensors were investigated for use in the nondestructive evaluation of aging aircraft. Specifically, optical fiber sensors for detection and location of impacts on a surface, and for detection of corrosion in metals were developed. The use of neural networks was investigated for determining impact location by processing the output of a network of fiberoptic strain sensors distributed on a surface. This approach employs triangulation to determine location by comparing the arrival times at several sensors, of the acoustic signal generated by the impact. For this study, a neural network simulator running on a personal computer was used to train a network using a back-propagation algorithm. Fiber optic extrinsic Fabry-Perot interferometer (EFPI) strain sensors are attached to or embedded in the surface, so that stress waves emanating from an impact can be detected. The ability of the network to determine impact location by time-or-arrival of acoustic signals was assessed by comparing network outputs with actual experimental results using impacts on a panel instrumented with optical fiber sensors. Using the neural network to process the sensor outputs, the impact location can be inferred to centimeter range accuracy directly from the arrival time data. In addition, the network can be trained to determine impact location, regardless of material anisotropy. Results demonstrate that a back-propagation network identifies impact location for an anisotropic graphite/bismaleimide plate with the same accuracy as that for an isotropic aluminum plate. Two different approaches were investigated for the development of fiber optic sensors for corrosion detection in metals, both utilizing optical fiber sensors with metal coatings. In the first approach, an extrinsic Fabry-Perot interferometric fiber optic strain sensor was placed under tensile stress, and while in the resulting strained position, a thick coating of metal was applied. Due to an increase in the quantity of material, the sensor does not return to its original position upon removal of the applied stress, and some residual strain is maintained within the sensor element. As the metal thickness decreases due to corrosion, this strain is released, providing the sensing mechanism for corrosion detection. In the second approach, photosensitive optical fibers with long period Bragg gratings in the core were coated with metal. The Bragg gratings serve to couple core modes at discrete wavelengths to cladding modes. Since cladding modes interact with the metal coating surrounding the fiber cladding, the specific wavelengths coupled from core to cladding depend on the refractive index of the metal coating. Therefore, as the metal corrodes, the resulting change in index of the coating may be measured by measuring the change in wavelength of the coupled mode. Results demonstrate that both approaches can be successfully used to track the loss in metal coating on the optical fiber sensors due to corrosion.
Schindler, Paul↗
Raman Study of Uncoated and P-bn/sic-coated Hi-nicalon Reinforced Celsian Matrix Composites: Residual Stress in the Fibers - Part 2
Band shifts on Raman spectra were used to assess, at a microscopic scale, the residual strain existing in Hi-Nicalon fibers reinforcing celsian matrix composites. Uncoated as well as p-BN/SiC- and p-B(Si)N/SiC-coated Hi-Nicalon fibers were used as the reinforcements. We unambiguously conclude that the fibers are in a state of compressive residual stress. Quantitative determination of the residual stress was made possible by taking into account the heating induced by laser probing and by using a reference line, of fixed wavenumber. We found fiber compressive residual stress values between 110 and 960 MPa depending on the fiber/matrix coating in the composite. A stress relaxation-like phenomenon was observed at the surface of p-BN/SiC-coated Hi-Nicalon fibers whereas the uncoated or p-B(Si)N/SiC-coated Hi-Nicalon fibers did not show any stress relaxation in the Celsian matrix composites.
Gouadec, Gwenael↗
Proposed framework for thermomechanical life modeling of metal matrix composites
The framework of a mechanics of materials model is proposed for thermomechanical fatigue (TMF) life prediction of unidirectional, continuous-fiber metal matrix composites (MMC's). Axially loaded MMC test samples are analyzed as structural components whose fatigue lives are governed by local stress-strain conditions resulting from combined interactions of the matrix, interfacial layer, and fiber constituents. The metallic matrix is identified as the vehicle for tracking fatigue crack initiation and propagation. The proposed framework has three major elements. First, TMF flow and failure characteristics of in situ matrix material are approximated from tests of unreinforced matrix material, and matrix TMF life prediction equations are numerically calibrated. The macrocrack initiation fatigue life of the matrix material is divided into microcrack initiation and microcrack propagation phases. Second, the influencing factors created by the presence of fibers and interfaces are analyzed, characterized, and documented in equation form. Some of the influences act on the microcrack initiation portion of the matrix fatigue life, others on the microcrack propagation life, while some affect both. Influencing factors include coefficient of thermal expansion mismatch strains, residual (mean) stresses, multiaxial stress states, off-axis fibers, internal stress concentrations, multiple initiation sites, nonuniform fiber spacing, fiber debonding, interfacial layers and cracking, fractured fibers, fiber deflections of crack fronts, fiber bridging of matrix cracks, and internal oxidation along internal interfaces. Equations exist for some, but not all, of the currently identified influencing factors. The third element is the inclusion of overriding influences such as maximum tensile strain limits of brittle fibers that could cause local fractures and ensuing catastrophic failure of surrounding matrix material. Some experimental data exist for assessing the plausibility of the proposed framework.
Halford, Gary R.↗
Forward Skirt Structural Testing on the Space Launch System (SLS) Program
Structural testing was performed to evaluate heritage forward skirts from the Space Shuttle program for use on the Space Launch System (SLS) program. One forward skirt is located in each solid rocket booster. Heritage forward skirts are aluminum 2219 welded structures. Loads are applied at the forward skirt thrust post and ball assembly. Testing was needed because SLS ascent loads are roughly 40% higher than Space Shuttle loads. Testing objectives were to determine margins of safety, demonstrate reliability, and validate analytical models. Two forward skirts were structurally tested using the test configuration. The test stand applied loads to the thrust post. Four hydraulic actuators were used to apply axial load and two hydraulic actuators were used to apply radial and tangential loads. The first test was referred to as FSTA-1 (Forward Skirt Structural Test Article) and was performed in April/May 2014. The purpose of FSTA-1 was to verify the ultimate capability of the forward skirt subjected to ascent ultimate loads. Testing consisted of two liftoff load cases taken to 100% limit load followed by an ascent load case taken to 110% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The second test was referred to as FSTA-2 and performed in July/August of 2014. The purpose of FSTA-2 was to verify the ultimate capability of the forward skirt subjected to liftoff ultimate loads. Testing consisted of six liftoff load cases taken to 100% limit load followed by the six liftoff cases taken to 140% limit load. Two ascent load cases were then tested to 100% limit load. The forward skirt was unloaded to no load after each test case. Lastly, the forward skirt was tested to 140% limit and then to failure using the ascent loads. The forward skirts on FSTA-1 and FSTA-2 successfully carried all applied liftoff and ascent load cases. Both FSTA-1 and FSTA-2 were tested to failure by increasing the ascent loads. Failure occurred in the forward skirt thrust post radius. The forward skirts on FSTA-1 and FSTA-2 had nearly identical failure modes. FSTA-1 failed at 1.72 times limit load and FSTA-2 failed at 1.62 times limit load. This difference is primarily attributed to variation in material properties in the thrust post region. Test data were obtained from strain gages, deflection gages, ARAMIS digital strain measurement, acoustic emissions, and high-speed video. Strain gage data and ARAMIS strain were compared to finite element (FE) analysis predictions. Both the forward skirt and tooling were modeled. This allows the analysis to simulate the loading as close as possible to actual test configuration. FSTA-1 and FSTA-2 were instrumented with over 200 strain gages to ensure all possible failure modes could be captured. However, it turned out that three gages provided critical strain data. One was located in the post bore and two on the post radius. More gages were not specified due to space limitations and the desire to not interfere with the use of the ARAMIS system on the post radius. Measured strains were compared to analysis results for the load cycle to failure. Note that FSTA-1 gages were lost before failure was reached. FSTA-2 gages made it to the failure load but one of the radius gages was lost before testing began. This gage was not replaced because of the time and cost associated with disassembly of the test structure. Correlation to analysis was excellent for FSTA-1. FSTA-2 was not quite as good because there was more residual strain from previous load cycles. FSTA-2 was loaded and unloaded with 12 liftoff cases and two ascent cases before taking the skirt to failure. FSTA-1 only had two liftoff cases and one ascent case before taking the skirt to failure. The ARAMIS system was used to determine strain at the post radius by processing digital images of a speckled paint pattern. Digital cameras recorded images of the speckled paint pattern. ARAMIS strain results for FSTA-2 just prior to failure. Note a high strain location develops near the left side. This high strain compares well to analysis prediction for both FSTA-1 and FSTA-2. The strain at this location was also plotted versus limit load. Both FSTA-1 and FSTA-2 had excellent correlation between ARAMIS and analysis strains. Acoustic emission (AE) sensors were used to monitor for damage formation that may occur during testing (e.g., crack formation and growth or propagation). AE was very important because after disassembly of FSTA-1, a crack was observed in the ball fitting radius. The ball fitting did not crack on FSTA-2. AE data was used to reconstruct when the crack occurred. The AE energy versus time plot for FSTA. The energy increased considerably at 850 seconds (152% limit load), indicating a crack could have formed at this point. The only visual evidence found that could have corresponded to this was the crack that initiated in the ball fitting. The cracks in the forward skirt aluminum structures would likely have been lower energy due to a lower modulus and all that were found after failure correlated to occurring after the initial crack in the post radius. This was verified by high-speed cameras used to record the failure.
Lohrer, J. D.↗
Impact Ice Adhesion at NASA Glenn: Current Experimental Methods and Supporting Measurements
When examining the literature on the adhesion strength of impact ice, there have been a wide range of methodologies tried to measure the required stresses to induce interfacial delamination. Utilizing the Icing Research Tunnel at the NASA Glenn Research Center to generate the impact ice required for this work, several different mechanical tests have been and are being developed to determine the stresses along the interface between ice and coupon. This set of tests includes the technical mature modified lap joint test which has been used to conduct ice adhesion studies through a wide sweep of icing conditions. To conduct in situ ice adhesion measurements inside of the Icing Research Tunnel, several new experiments are currently being developed to make ice adhesion measurements during and immediately after ice accretion. In addition to these experimental methods, several supporting measurement techniques have been developed to allow for a better understanding on the influence of icing cloud conditions on the mechanical behavior of impact ice. Digital image correlation has been successfully implemented to augment the data generated by the modified lap joint test with full field surface displacement and strain measurements which allow for insight into the deformation processes present during a test. Both optical microscopy of impact ice samples along with ice replication techniques have been used to study the grain structure of the impact ice. This has led to a deeper understanding of the results from the modified lap joint method and how the structure of impact ice changes as it is accreted during an icing spray. The freezing process of impact ice generated by supercooled liquid water is not a volume conserving process, which leads to the presence of residual strains along the interface between ice and substrate. These strains have been observed using both a simplified flat geometry and a representative airfoil. The data gathered by these experimental adhesion methods and supporting measurements allows for a comprehensive understanding on the behavior of impact ice which will be critical to the development of future ice shedding models.
Ice Adhesion↗
Impact Ice Adhesion at NASA Glenn: Current Experimental Methods and Supporting Measurements
When examining the literature on the adhesion strength of impact ice, there have been a wide range of methodologies tried to measure the required stresses to induce interfacial delamination. Utilizing the Icing Research Tunnel at the NASA Glenn Research Center to generate the impact ice required for this work, several different mechanical tests have been and are being developed to determine the stresses along the interface between ice and coupon. This set of tests includes the technical mature modified lap joint test which has been used to conduct ice adhesion studies through a wide sweep of icing conditions. To conduct in situ ice adhesion measurements inside of the Icing Research Tunnel, several new experiments are currently being developed to make ice adhesion measurements during and immediately after ice accretion. In addition to these experimental methods, several supporting measurement techniques have been developed to allow for a better understanding on the influence of icing cloud conditions on the mechanical behavior of impact ice. Digital image correlation has been successfully implemented to augment the data generated by the modified lap joint test with full field surface displacement and strain measurements which allow for insight into the deformation processes present during a test. Both optical microscopy of impact ice samples along with ice replication techniques have been used to study the grain structure of the impact ice. This has led to a deeper understanding of the results from the modified lap join method and how the structure of impact ice changes as it is accreted during an icing spray. The freezing process of impact ice generated by supercooled liquid water is not a volume conserving process, which leads to the presence of residual strains along the interface between ice and substrate. These strains have been observed using both a simplified flat geometry and a representative airfoil. The data gathered by these experimental adhesion methods and supporting measurements allows for a compressive understanding on the behavior of impact ice which will be critical to the development of future ice shedding models.
Ice Adhesion↗