Fatigue- a complex subject - some simple approximations
Cyclic-load method of studying crack propagation and fatigue life in material testing
MATERIAL TESTING↗
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A radio-frequency transparent, impact energy absorbing material.
RF transparent impact energy absorbing planetary landing craft material tests, examining various glass-cloth reinforced plastic honeycomb specimens
IMPACT TEST↗
Design of smart 3D-digital X-ray microtomographic scanners for non-destructive testing of materials and components of electronic devices with a multilayered structure
The article studies the operating procedures of an X-ray microtomographic scanner and the module of reconstruction and analysis 3D-image of a test sample in particular. An algorithm for 3D-image reconstruction based on image shadow projections and mathematical methods of the processing are described. Chapter 1 describes the basic principles of X-ray tomography and general procedures of the device developed. Chapters 2 and 3 are devoted to the problem of resources saving by the system during the X-ray tomography procedure, which is achieved by preprocessing of the initial shadow projections. Preprocessing includes background noise removing from the images, which reduces the amount of shadow projections in general and increases the efficiency of the group shadow projections compression. Chapter 4 covers general procedures of defect search, which is based on vector analysis principles. In conclusion, the main applications of X-ray tomography are presented.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
Mechanical impact tests of materials in oxygen effects of contamination
The effect of contaminants on the mechanical impact sensitivity of Teflon, stainless steel, and aluminum in a high-pressure oxygen environment was investigated. Uncontaminated Teflon did not ignite under the test conditions. The liquid contaminants - cutting oil, motor lubricating oil, and toolmaker dye - caused Teflon to ignite. Raising the temperature lowered the impact energy required for ignition. Stainless steel was insensitive to ignition under the test conditions with the contaminants used. Aluminum appeared to react without contaminants under certain test conditions; however, contamination with cutting oil, motor lubricating oil, and toolmakers dye increased the sensitivity of aluminum to mechanical impact. The grit contaminants silicon dioxide and copper powder did not conclusively affect the sensitivity of aluminum.
Ordin, P. M.↗
Unmanned Vehicle Material Flammability Test
Microgravity fire behaviour remains poorly understood and a significant risk for spaceflight An experiment is under development that will provide the first real opportunity to examine this issue focussing on two objectives: a) Flame Spread. b) Material Flammability. This experiment has been shown to be feasible on both ESA's ATV and Orbital Science's Cygnus vehicles with the Cygnus as the current base-line carrier. An international topical team has been formed to develop concepts for that experiment and support its implementation: a) Pressure Rise prediction. b) Sample Material Selection. This experiment would be a landmark for spacecraft fire safety with the data and subsequent analysis providing much needed verification of spacecraft fire safety protocols for the crews of future exploration vehicles and habitats.
Urban, David L.↗
Applications of Automation Methods for Nonlinear Fracture Test Analysis
As fracture mechanics material testing evolves, the governing test standards continue to be refined to better reflect the latest understanding of the physics of the fracture processes involved. The traditional format of ASTM fracture testing standards, utilizing equations expressed directly in the text of the standard to assess the experimental result, is self-limiting in the complexity that can be reasonably captured. The use of automated analysis techniques to draw upon a rich, detailed solution database for assessing fracture mechanics tests provides a foundation for a new approach to testing standards that enables routine users to obtain highly reliable assessments of tests involving complex, non-linear fracture behavior. Herein, the case for automating the analysis of tests of surface cracks in tension in the elastic-plastic regime is utilized as an example of how such a database can be generated and implemented for use in the ASTM standards framework. The presented approach forms a bridge between the equation-based fracture testing standards of today and the next generation of standards solving complex problems through analysis automation.
Allen, Phillip A.↗
Simple effective conservative treatment of uncertainty from sparse samples of random functions
This paper examines the variability of predicted responses when multiple stress-strain curves (reflecting variability from replicate material tests) are propagated through a finite element model of a ductile steel can being slowly crushed. Over 140 response quantities of interest (including displacements, stresses, strains, and calculated measures of material damage) are tracked in the simulations. Each response quantity’s behavior varies according to the particular stress-strain curves used for the materials in the model. We desire to estimate response variability when only a few stress-strain curve samples are available from material testing. Propagation of just a few samples will usually result in significantly underestimated response uncertainty relative to propagation of a much larger population that adequately samples the presiding random-function source. A simple classical statistical method, Tolerance Intervals, is tested for effectively treating sparse stress-strain curve data. The method is found to perform well on the highly nonlinear input-to-output response mappings and non-standard response distributions in the can-crush problem. The results and discussion in this paper support a proposition that the method will apply similarly well for other sparsely sampled random variable or function data, whether from experiments or models. Finally, the simple Tolerance Interval method is also demonstrated to be very economical.
36 MATERIALS SCIENCE↗
Non-destructive evaluation method employing dielectric electrostatic ultrasonic transducers
An acoustic nonlinearity parameter (.beta.) measurement method and system for Non-Destructive Evaluation (NDE) of materials and structural members novelly employs a loosely mounted dielectric electrostatic ultrasonic transducer (DEUT) to receive and convert ultrasonic energy into an electrical signal which can be analyzed to determine the .beta. of the test material. The dielectric material is ferroelectric with a high dielectric constant .di-elect cons.. A computer-controlled measurement system coupled to the DEUT contains an excitation signal generator section and a measurement and analysis section. As a result, the DEUT measures the absolute particle displacement amplitudes in test material, leading to derivation of the nonlinearity parameter (.beta.) without the costly, low field reliability methods of the prior art.
Yost, William T.↗
Design guide: Designing and building high voltage power supplies, volume 2
This report contains an accumulation of publications and analyses aimed at developing guidelines for improving both high voltage and low voltage power supplies for the U.S. Air Force systems command. It is the intent of the report to supply good design and manufacturing techniques for the packaging and the building of high quality, reliable, long-life power supplies. These data are based on the wealth of engineering practices established by design and manufacturing engineers. The contents are: Fundamentals of Insulation: Gases, Liquid Dielectrics, Solid Insulation; Environment: Pressure, Particulates, Environmental Interactions with Space Power Systems, Surface Charging, System Design Criteria; Configuration and Design Data: Designs, Transients, Grounding and Bonding, Thermal Control; Materials and Processes: Insulation, Processes, Process Variables; Manufacturing: Yield, Government and Industrial Survey, Analysis, Problem Areas and Suggested Solutions, Designs That Have Worked in High Voltage Equipment, Manufacturing Summary; and Tests: Performance, Insulation Tests, Materials Testing, Component and Equipment Tests, Performance Testing, Facility and Environment, Accelerated Life Test; Maintenance and Repair: Maintenance, Test Sets, Pilots and Crewmen, Air Logistic Centers, Design Problem Recommendations.
W G Dunbar↗
The JPL Cryogenic Dilatometer: Measuring the Thermal Expansion Coefficient of Aerospace Materials
This slide presentation details the cryogenic dilatometer, which is used by JPL to measure the thermal expansion coefficient of materials used in Aerospace. Included is a system diagram, a picture of the dilatometer chamber and the laser source, a description of the laser source, pictures of the interferometer, block diagrams of the electronics and software and a picture of the electronics, and software. Also there is a brief review of the accurace.error budget. The materials tested are also described, and the results are shown in strain curves, JPL measured strain fits are described, and the coefficient of thermal expansion (CTE) is also shown for the materials tested.
dilatometer↗
Dissolved Air Flotation for Rapid Dewatering and Separation of Legacy Sludge Wastes - 19065
As a low footprint, high efficiency separation process, Dissolved Air Floatation (DAF) could effectively be retrofitted into existing waste management facilities at nuclear sites such Sellafield and Hanford to rapidly separate particulates from aqueous suspensions. The simplicity (no moving parts) and size of this technology coupled with low cost of construction and reagent purchase would also be ideal for ease of facility decommissioning with minimum impact to secondary waste generation. For this study, methyl isobutyl carbinol (MIBC) was used in this research as a frothing agent to produce a preferable stable foam. Mg(OH){sub 2} was selected as a test material as it is the result of long term corrosion of Magnox fuel in UK nuclear fuel storage ponds. Due to the cationic nature of the Mg(OH){sub 2} test material, the anionic surfactant, Sodium Dodecyl Sulphate (SDS) was used as collector to modify the surface properties to increase hydrophobicity. The performance of anionic SDS in floating 2.5%v/v Mg(OH){sub 2} was compared to the adsorption isotherm of SDS on Mg(OH){sub 2} to determine monolayer coverage surfactant dose which was investigated using Total Organic Carbon (TOC). SDS was found to increase particulate recovery to 93% with some water carry-over observed and it was found that particle bubble attachment was optimum for a select particle size distribution. This study proved that potential application of flotation as an efficient viable dewatering technique for common magnesium hydroxide based legacy wastes, using cheap, readily available collector and frother agents. (authors)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Genotoxicity of carbon nanofibers: Are they potentially more or less dangerous than carbon nanotubes or asbestos?
The production of carbon nanofibers and nanotubes (CNF/CNT) and their composite products is increasing globally. CNF are generating great interest in industrial sectors such as energy production and electronics, where alternative materials may have limited performance or are produced at a much higher cost. However, despite the increasing industrial use of carbon nanofibers, information on their potential adverse health effects is limited. In the current study, we examine the cytotoxic and genotoxic potential of carbon-based nanofibers (Pyrograf (registered) -III) and compare this material with the effects of asbestos fibers (crocidolite) or single-walled carbon nanotubes (SWCNT). The genotoxic effects in the lung fibroblast (V79) cell line were examined using two complementary assays: the comet assay and micronucleus (MN) test. In addition, we utilized fluorescence in situ hybridization to detect the chromatin pan-centromeric signals within the MN indicating their origin by aneugenic (chromosomal malsegregation) or clastogenic (chromosome breakage) mechanisms. Cytotoxicity tests revealed a concentration- and time-dependent loss of V79 cell viability after exposure to all tested materials in the following sequence: asbestos > CNF > SWCNT. Additionally, cellular uptake and generation of oxygen radicals was seen in the murine RAW264.7 macrophages following exposure to CNF or asbestos but not after administration of SWCNT. DNA damage and MN induction were found after exposure to all tested materials with the strongest effect seen for CNF. Finally, we demonstrated that CNF induced predominately centromere-positive MN in primary human small airway epithelial cells (SAEC) indicating aneugenic events. Further investigations are warranted to elucidate the possible mechanisms involved in CNF-induced genotoxicity.
60 APPLIED LIFE SCIENCES↗
Cycom 977-2 Composite Material: Impact Test Results
The reaction frequency data from 13A testing by MSFC and WSTF appear well behaved for the sample number used by each and exhibit the same type of energy level dependency. The reaction frequency shift in energy level is unexplained at this time. All the 13A data suggest that only a small amount of material is consumed when reactions take place. At ambient pressure, most of not all reactions are quenched as indicated by the small mass loss. As test pressure is increased in LOX using 13B results. Cycom does not support initiation of reactions or propagations of reactions in GOX at 100 psis based on tests at MSFC and WSTF at 72 ft-lb impact energy. No batch effect was identified in LOX or GOX.
Engel, Carl D.↗
Testing of materials for passive thermal control of space suits
An effort is underway to determine the coating material of choice for the AX-5 prototype hard space suit. Samples of 6061 aluminum have been coated with one of 10 selected metal coatings, and subjected to corrosion, abrasion, and thermal testing. Changes in reflectance after exposure are documented. Plated gold exhibited minimal degradation of optical properties. A computer model is used in evaluating coating thermal performance in the EVA environment. The model is verified with an experiment designed to measure the heat transfer characteristics of coated space suit parts in a thermal vacuum chamber. Details of this experiment are presented.
Squire, Bernadette↗
Managing the Digital Thread for Structural Applications With Fit for Purpose Materials
With the increased emphasis on reducing the cost and time to market of new materials, the need for analytical tools that enable the virtual design and optimization of materials throughout their processing - internal structure - property - performance envelope, along with the capturing and storing of the associated material and model information across its lifecycle, has become critical. This need is also fueled by the demands for higher efficiency in material testing; consistency, quality and traceability of data; product design; engineering analysis; as well as control of access to proprietary or sensitive information. Consequently, at NASA Glenn Research Center a robust information management system that manages the digital thread across the full material life (i.e., capture, analysis, maintenance, and dissemination of data) cycle directed at the design of ‘fit-for-purpose materials’ is under development. To this end the Application Table has been incorporated within NASA Glenn Research Center’s ICME Information Management framework within the ANSYS Granta MI tool. The Application Table provides a place where material and structural application information/requirements can be linked to marry the “design-the-material” (structural engineering) and the “design-with-material” (material science) paradigms and thereby enable application-driven design and optimization of materials and structures. In additional several associated toolsets, specifically: AIMAOS (Automated Information Management Across Organizations and Scales), Py MILab, and JARIMIS (Just A Rather Intelligent Material Interrogation System) are also under development to assist in the judicious automation of this process. AIMOAS offers users an interactive graphical user interface for connecting material information management systems with both commercial and in-house simulation tools at various length scales to enable such automation in the handoff across scales and maintenance of material digital twins and the digital thread. Py MILab, is an automatic framework for the capture, analysis, maintenance, and storage of material test data. Py MILab uses a modular approach for capturing raw data, analyzing the data, and storing the data in a database, interfaced by neutral file structures, to promote plug-and-play capabilities for various analysis types. Finally, JARIMIS is an expert system that integrates various materials informatics tools (e.g., MicroNet, Surrogate ML models, ANSYS Granta MI, etc.) to enable inverse design of materials and facilitate the application of machine learning (ML) and data science with human in the loop decision making to rapidly discover and optimize new materials.
Digital Transformation↗
Thermal Analysis of Irradiation Experiments in the ATR
Reactor material testing in the INL's Advanced Test Reactor (ATR) involves modeling and simulation of each experiment to accurately determine the irradiation temperature. This paper describes thermal analysis of capsule experiments using gas gap temperature control and provides data on recent material tests that validate the modeling results. Static capsule experiments and lead-out capsule experiments are discussed. The source of temperature variation in capsule experiments and ways to mitigate these variations are also explained. Two examples of instrumented lead-out capsule experiments, TMIST-1 and UCSB-2, are presented. A comparison of measured and calculated temperatures is used to validate the thermal models and to ascertain the accuracy of the calculated temperature.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Ignition delays, heats of combustion, and reaction rates of aluminum alkyl derivatives used as ignition and combustion enhancers for supersonic combustors
The work was based on adapting an apparatus and procedure developed at Southwest Research Institute for rating the ignition quality of fuels for diesel engines. Aluminum alkyls and various Lewis-base adducts of these materials, both neat and mixed 50/50 with pure JP-10 hydrocarbon, were injected into the combustion bomb using a high-pressure injection system. The bomb was pre-charged with air that was set at various initial temperatures and pressures for constant oxygen density. The ignition delay times were determined for the test materials at these different initial conditions. The data are presented in absolute terms as well as comparisons with the parent alkyls. The relative heats of reaction of the various test materials were estimated based on a computation of the heat release, using the pressure data recorded during combustion in the bomb. In addition, the global reaction rates for each material were compared at a selected tmperature and pressure.
Ryan, T. W., III↗
Experimental Study of RF Pulsed Heating
Cyclic thermal stresses produced by rf pulsed heating can be the limiting factor on the attainable reliable gradients for room temperature linear accelerators. This is especially true for structures that have complicated features for wakefield damping. These limits could be pushed higher by using special types of copper, copper alloys, or other conducting metals in constructing partial or complete accelerator structures. Here we present an experimental study aimed at determining the potential of these materials for tolerating cyclic thermal fatigue due to rf magnetic fields. A special cavity that has no electric field on the surface was employed in these studies. The cavity shape concentrates the magnetic field on one flat surface where the test material is placed. The materials tested in this study have included oxygen free electronic grade copper, copper zirconium, copper chromium, hot isostatically pressed copper, single crystal copper, electroplated copper, Glidcop(reg. sign), copper silver, and silver plated copper. The samples were exposed to different machining and heat treatment processes prior to rf processing. Each sample was tested to a peak pulsed heating temperature of approximately 110 C and remained at this temperature for approximately 10 x 10 6 rf pulses. In general, the results showed the possibility of pushing the gradient limits due to pulsed heating fatigue by the use of copper zirconium and copper chromium alloys.
36 MATERIALS SCIENCE↗