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Fixture used to evalute properties of O-rings of various materials. Hydraulic actuator positions plug in housing, creating controlled, variable gap in O-ring glands formed by grooves in plug and by inner wall of housing. Creates controlled axial and radial gaps between sealing surfaces around ring so effectiveness of material in maintaining seal determined under dynamic conditions.
Surface flawed specimens of 2219-T87 and 6Al-4V STA titanium weldments were tested to determine static failure modes, failure strength, and fatigue flaw growth characteristics. Thicknesses selected for this study were purposely set at values where, for most test conditions, abrupt instability of the flaw at fracture would not be expected. Static tests for the aluminum weldments were performed at room, LN2 and LH2 temperatures. Titanium static tests for tests were performed at room and LH2 temperatures. Results of the static tests were used to plot curves relating initial flaw size to leakage- or failure-stresses (i.e. "failure" locus curves). Cyclic tests, for both materials, were then performed at room temperature, using initial flaws only slightly below the previously established failure locus for typical proof stress levels. Cyclic testing was performed on pairs of specimens, one with and one without a simulated proof test cycle. Comparisons were made then to determine the value and effect of proof testing as affected by the various variables of proof and operating stress, flaw shape, material thickness, and alloy.
This research investigates the response of a fiberless 13 layer hot isostatically pressed Ti-15-3 laminate to creep, constant strain rate, and cyclic constant strain rate loading at temperatures ranging from 482C to 649C. Creep stresses from 48 to 260 MPa and strain rates of .0001 to .01 m/m/sec were used. Material parameters for three unified constitutive models (Bodner-Partom, Miller, and Walker models) were determined for Ti-15-3 from the experimental data. Each of the three models was subsequently incorporated into a rule of mixtures and evaluated for accuracy and ease of use in predicting the thermoviscoplastic response of unidirectional metal matrix composite laminates (both 0 and 90). The laminates were comprised of a Ti-15-3 matrix with 29 volume percent SCS6 fibers. The predicted values were compared to experimentally determined creep and constant strain rate data. It was found that all three models predicted the viscoplastic response of the 0 specimens reasonably well, but seriously underestimated the viscoplastic response of the 90 specimens. It is believed that this discrepancy is due to compliant and/or weak fiber-matrix interphase. In general, it was found that of the three models studied, the Bodner-Partom model was easiest to implement, primarily because this model does not require the use of cyclic constant strain rate tests to determine the material parameters involved. However, the version of the Bodner-Partom model used in this study does not include back stress as an internal state variable, and hence may not be suitable for use with materials which exhibit a pronounced Baushinger effect. The back stress is accounted for in both the Walker and Miller models; determination of the material parameters associated with the Walker model was somewhat easier than in the Miller model.
A research program has been developed to quantify the effects of the microstructure of a woven ceramic matrix composite and its variability on the effective properties and response of the material. In order to characterize and quantify the variations in the microstructure of a five harness satin weave, chemical vapor infiltrated (CVI) SiC/SiC composite material, specimens were serially sectioned and polished to capture images that detailed the fiber tows, matrix, and porosity. Open source quantitative image analysis tools were then used to isolate the constituents, from which two dimensional finite element models were generated which approximated the actual specimen section geometry. A simplified elastic-plastic model, wherein all stress above yield is redistributed to lower stress regions, is used to approximate the progressive damage behavior for each of the composite constituents. Finite element analyses under in-plane tensile loading were performed to examine how the variability in the local microstructure affected the macroscopic stress-strain response of the material as well as the local initiation and progression of damage. The macroscopic stress-strain response appeared to be minimally affected by the variation in local microstructure, but the locations where damage initiated and propagated appeared to be linked to specific aspects of the local microstructure.
The growth of naturally-initiated small cracks under a variety of constant amplitude and variable amplitude load sequences is examined for several airframe materials: the conventional aluminum alloys, 2024-T3 and 7075-T6, the aluminum-lithium alloy, 2090-T8E41, and 4340 steel. Loading conditions investigated include constant amplitude loading at R = 0.5, 0, -1 and -2 and the variable amplitude sequences FALSTAFF, Mini-TWIST and FELIX/28. Crack growth was measured at the root of semicircular edge notches using acetate replicas. Crack growth rates are compared on a stress intensity factor basis, to those for large cracks to evaluate the extent of the small crack effect in each alloy. In addition, the various alloys are compared on a crack initiation and crack growth morphology basis.
The growth of naturally-initiated small cracks under a variety of constant amplitude and variable amplitude load sequences is examined for several airframe materials: the conventional aluminum alloys, 2024-T3 and 7075-T6, the aluminum-lithium alloy, 2090-T8E41 and 4340 steel. Loading conditions investigated include constant amplitude loading at R = 0.5, 0, -1 and -2 and the variable amplitude sequences FALSTAFF, Mini-TWIST, and FELIX/28. Crack growth was measured at the root of semicircular edge notches using acetate replicas. Crack growth rates are compared on a stress intensity factor basis, to those for large cracks to evaluate the extent of the small crack effect in each alloy. In addition, the various alloys are compared on a crack initiation and crack growth morphology basis.
Promoted combustion testing (outlined in the ASTM G124 “Standard Test Method for Determining the Combustion Behavior of Metallic Materials in Oxygen Enriched Atmospheres”) refers to a useful testing method to evaluate how metallic materials will behave when combusted in environments with high oxygen concentrations, elevated pressure, or both. These tests yield data which is useful for engineers and scientists from a variety of industries who need and rely on oxygen systems. Oxygen Compatibility Assessments (OCA’s) are vital for ensuring that materials will be safe for use, and these assessments rely on data from OCA’s or interpolation if a desired pressure/concentration is outside of previously tested bounds. It was identified that these bounds leave out significant areas of data for materials which are tested at high pressures (above 1500 psi) and variable oxygen concentrations (with nitrogen as the diluent gas). For this reason, the authors posited that conducting promoted combustion testing on materials above 1500 psi and in various concentrations of oxygen would be incredibly useful in future analyses for oxygen compatibility with similar environments (such as breathing air) as well as for further understanding of how materials behave at very high pressures (such as 10000 psi). Two materials were selected which are commonly used in industry today - 316 stainless steel and 6061 aluminum – and they were tested and analyzed for the purposes of this study.
A thermal protection system that reduces a mismatch of thermal expansion coefficients CTE between a first material layer (CTE1) and a second material layer (CTE2) at a first layer-second layer interface. A portion of aluminum borosilicate (abs) or another suitable additive (add), whose CTE value, CTE(add), satisfies (CTE(add)-CTE1)(CTE(add)-CTE2)<0, is distributed with variable additive density,.rho.(z;add), in the first material layer and/or in the second material layer, with.rho.(z;add) near the materials interface being relatively high (alternatively, relatively low) and.rho.(z;add) in a region spaced apart from the interface being relatively low (alternatively, relatively high).
The paper is concerned with the realistic case of two-dimensional random motion of a membrane with bending stiffness supported on a viscoelastic spring substrate and on an elastic base plate under both subsonic and supersonic boundary layer turbulence. The cross-power spectral density of surface displacements is solved in terms of design variables of the compliant wall - such as the dimensions and material properties of the membrane (Mylar), substrate (PVC foam), and panel (aluminum) - so that a sensitivity analysis can be made to examine the influence of each design variable on the surface response statistics. Three numerical examples typical of compliant wall design are worked out and their response statistics in relation to wave drag and roughness drag are assessed. The results can serve as a guideline for experimental investigation of the drag reduction concept through the use of a compliant wall.
The variable terrain tilt platform (VTTP) is a means of providing simulated terrain for mobility testing of engineering models of the Mars Exploration Rovers. The VTTP could also be used for testing the ability of other robotic land vehicles (and small vehicles in general) to move across terrain under diverse conditions of slope and surface texture, and in the presence of obstacles of various sizes and shapes. The VTTP consists mostly of a 16-ft-(4.88-m)-square tilt table. The tilt can be adjusted to any angle between 0 (horizontal) and 25 . The test surface of the table can be left bare; can be covered with hard, high-friction material; or can be covered with sand, gravel, and/or other ground-simulating material or combination of materials to a thickness of as much as 6 in. (approx. 15 cm). Models of rocks, trenches, and other obstacles can be placed on the simulated terrain. For example, for one of the Mars- Rover tests, a high-friction mat was attached to the platform, then a 6-in.- ( 15 cm) deep layer of dry, loose beach sand was deposited on the mat. The choice of these two driving surface materials was meant to bound the range of variability of terrain that the rover was expected to encounter on the Martian surface. At each of the different angles at which tests were performed, for some of the tests, rocklike concrete obstacles ranging in height from 10 to 25 cm were placed in the path of the rover (see figure). The development of the VTTP was accompanied by development of a methodology of testing to characterize the performance and modes of failure of a vehicle under test. In addition to variations in slope, ground material, and obstacles, testing typically includes driving up-slope, down-slope, cross-slope, and at intermediate angles relative to slope. Testing includes recording of drive-motor currents, wheel speeds, articulation of suspension mechanisms, and the actual path of the vehicle over the simulated terrain. The collected data can be used to compute curves that summarize torque, speed, power-demand, and slip characteristics of wheels during the traverse.
Thermal conductivity data were obtained by the axial one-dimensional heat flow method for a cylindrical rod 3.6 mm in diameter and 23 cm long with an electric heater at one end and a temperature controlled sink at the other. Variability of this iron was studied by means of electrical residual resistivity ratio measurements on 63 specimens. This study showed that with a two-hour anneal at 1000 C one can obtain a thermal conductivity Standard Reference Material that has variability of less than 1% in thermal conductivity.
Electrical products having organic materials functioning as pottants, encapsulants, and insulation coatings are commonly exposed to elevated conditions of temperature and humidity. In order to assess service life potential from this method of accelerated aging, it was empirically observed that service life seems proportional to an aging correlation which is the sum of temperature in degrees Celsius (t), and the relative humidity (RH) expressed in percent. Specifically, the correlation involves a plot of time-to-failure on a log scale versus the variable RH + T plotted on a linear scale. A theoretical foundation is provided for this empirically observed correlation by pointing out that the correlation actually involves a relationship between the electrical resistivity (or conductivity) of the organic material, and the variable RH + t. If time-to-failure is a result of total number of coulombs conducted through the organic material, then the correlation of resistivity versus RH + t is synonymous with the empirical correlation of time-to-failure versus RH + t.
Separator materials, ceramic to metal seals, cell plate polarization and impregnation processes, and plaque sintering data for study of variables in manufacture of nickel cadmium cells
As a result of significant progress in the reduction of fan and jet noise, there is growing concern regarding core noise. One method for achieving core noise reduction is via the use of acoustic liners. However, these liners must be constructed with materials suitable for high temperature environments and should be designed for optimum absorption of the broadband core noise spectrum. This paper presents results of tests conducted in the NASA Langley Liner Technology Facility to evaluate a variable-impedance ceramic matrix composite acoustic liner that offers the potential to achieve each of these goals. One concern is the porosity of the ceramic matrix composite material, and whether this might affect the predictability of liners constructed with this material. Comparisons between two variable-depth liners, one constructed with ceramic matrix composite material and the other constructed via stereolithography, are used to demonstrate this material porosity is not a concern. Also, some interesting observations are noted regarding the orientation of variable-depth liners. Finally, two propagation codes are validated via comparisons of predicted and measured acoustic pressure profiles for a variable-depth liner.
Charged-particle fluxes from breakdown events were studied. Methods to measure mass spectra and total emitted flux of neutral particles were developed. The design and construction of the specialized mass spectrometer was completed. Electrical breakdowns were initiated by a movable blunt contact touching the insulating surface. The contact discharge apparatus was used for final development of two different high-speed recording systems and for measurements of the composition of the materials given off by the discharge. It was shown that intense instantaneous fluxes of neutral particles were released from the sites of electrical breakdown events. A laser micropulse mass analyzer showed that visible discoloration at breakdown sites were correllated with the presence of iron on the polymer side of the film, presumably caused by punch-through to the Inconel backing. Kapton samples irradiated by an oxygen ion beam were tested. The irradiated samples were free of surface hydrocarbon contamination but otherwise behaved in the same way as the Kapton samples tested earlier. Only the two samples exposed to oxygen ion bombardment were relatively clean. This indicates an additional variable that should be considered when testing spacecraft materials in the laboratory.
Relative toxicity data for a large number of natural and synthetic polymeric materials are presented which were obtained by 11 pyrolysis and three flaming-combustion test methods. The materials tested include flexible and rigid polyurethane foams, different kinds of fabrics and woods, and a variety of commodity polymers such as polyethylene. Animal exposure chambers of different volumes containing mice, rats, or rabbits were used in the tests, which were performed over the temperature range from ambient to 800 C with and without air flow or recirculation. The test results are found to be sensitive to such variables as exposure mode, temperature, air flow and dilution, material concentration, and animal species, but relative toxicity rankings appear to be similar for many methods and materials. It is concluded that times to incapacitance and to death provide a more suitable basis for relative toxicity rankings than percent mortality alone, that temperature is the most important variable in the tests reported, and that variables such as chamber volume and animal species may not significantly affect the rankings.
The fatigue properties of modern powder metallurgy disk alloys can vary because of the different steps of materials and component processing and machining. Among these variables, the effects of nonmetallic inclusions introduced during the powder atomization and handling processes have been shown to significantly degrade low-cycle fatigue life. The levels of inclusion contamination have, therefore, been reduced to less than 1 part per million in state-of-the-art nickel disk powder-processing facilities. Yet the large quantities of compressor and turbine disks weighing from 100 to over 1000 lb have enough total volume and surface area for these rare inclusions to still be present and limit fatigue life. The objective of this study was to investigate the effects on fatigue life of these inclusions, as part of the Crack Resistant Disk Materials task within the Ultra Safe Propulsion Project. Inclusions were carefully introduced at elevated levels in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were then performed on extracted test specimens at 650 C. Analyses were performed to compare the low-cycle fatigue lives and failure initiation sites as functions of inclusion content and fatigue conditions. Powder of the nickel-base superalloy U720 was atomized in argon at Special Metals Corporation, Inc., using production-scale high-cleanliness powder-processing facilities and handling practices. The powder was then passed through a 270-mesh screen. One portion of this powder was set aside for subsequent consolidation without introduced inclusions. Two other portions of this powder were seeded with alumina inclusions. Small, polycrystalline soft (Type 2) inclusions of about 50 mm diameter were carefully prepared and blended into one powder lot, and larger hard (Type 1) inclusions of about 150 mm mean diameter were introduced into the other seeded portion of powder. All three portions of powder were then sealed in separate containers, hot isostatically pressurized, extruded, forged into subscale disks, and heat treated. Low-cycle-fatigue specimens were then extracted, machined, and tested. Fatigue tests were performed at 650 C in closed-loop servohydraulic testing machines using induction heating and axial extensometers. All tests were continued to failure, and fractographic evaluations were performed on all specimens to determine the crack initiation sites. A large majority of the failures in specimens with introduced inclusions occurred at cracks initiating from inclusions at the specimen surface, as shown for each type of inclusion in the following bar chart. The inclusions significantly reduced fatigue life from unseeded material levels, as shown in the bar chart. These effects were found to depend on the strain range, strain ratio, and inclusion size. Tests at lower strain ranges and higher strain ratios resulted in larger effects of inclusions on life. Inclusion effects on life were thereby maximized in tests at the lowest strain range of 0.6 percent and the most positive strain ratio of 0.5. Under these conditions, small Type 2 inclusions reduced life substantially-- about 20 times, whereas large Type 1 inclusions dramatically reduced life 100 times. These results clearly demonstrate that it is essential to include the effects of inclusions for realistic predictions of disk fatigue life. Important issues, including temperature dependence, crack initiation versus propagation, surface treatments, realistic disk features and machining, and realistic disk spin testing will be addressed to accurately model inclusion effects on disk fatigue life. Fatigue life varied from well over 105 cycles for no inclusions to a little over 103 cycles for 100-micrometer inclusions. A single crack initiating at a surface-connected seeded inclusion caused failure in each case.
The scope of the study is to investigate ways of controlling the microgravity environment of the International Space Station by means of a tethered system. Four main study tasks were performed. First, researchers analyzed the utilization of the tether systems to improve the lowest possible steady gravity level on the Space Station and the tether capability to actively control the center of gravity position in order to compensate for activities that would upset the mass distribution of the Station. The purpose of the second task was to evaluate the whole of the experiments performable in a variable gravity environment and the related beneficial residual accelerations, both for pure and applied research in the fields of fluid, materials, and life science, so as to assess the relevance of a variable g-level laboratory. The third task involves the Tethered Variable Gravity Laboratory. The use of the facility that would crawl along a deployed tether and expose experiments to varying intensities of reduced gravity is discussed. Last, a study performed on the Attitude Tether Stabilizer concept is discussed. The stabilization effect of ballast masses tethered to the Space Station was investigated as a means of assisting the attitude control system of the Station.