Development of energy dissipating plastic honeycomb Quarterly progress report, 1 Aug. - 31 Oct. 1966
Manufacturing modifications, and glass filler additions for dip resin used in honeycomb structures
MANUFACTURING↗
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Microstructural and material property changes in severely deformed Eurofer-97
Severe plastic deformation changes the microstructure and properties of steels, which may be favourable for their use in structural components of nuclear reactors. In this study, high-pressure torsion (HPT) was used to refine the grain structure of Eurofer-97, a ferritic/martensitic steel. Electron microscopy and X-ray diffraction were used to characterise the microstructural changes. Following HPT at room temperature to a maximum shear strain of 230, the average grain size reduced by a factor of ~30, with a marked increase in high-angle grain boundaries. Dislocation density also increased by more than one order of magnitude. The thermal stability of the deformed material was investigated via in-situ annealing during synchrotron X-ray diffraction. This revealed substantial recovery between 450 K – 800 K. Irradiation with 20 MeV Fe-ions to ~0.1 dpa caused a 20% reduction in dislocation density compared to the as-deformed material. However, HPT deformation prior to irradiation only had a minor effect in mitigating the irradiation-induced reductions in thermal diffusivity and surface acoustic wave velocity of the material. Microstructural and material property changes are dominated by deformation compared to irradiation. In light of this, the benefits of using HPT to improve the irradiation resistance of Eurofer-97 are limited. These results provide a multi-faceted view of the changes in ferritic/martensitic steels due to severe plastic deformation, and how these changes can be used to alter material properties.
ion-irradiation↗
High-Powered, Ultrasonically Assisted Thermal Stir Welding
This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a distance equal to the thickness of the material being welded. The TSW process can be significantly improved by reducing the draw forces. This can be achieved by reducing the friction forces between the weld workpieces and the containment plates. High-power ultrasonic (HPU) vibrations of the containment plates achieve friction reduction in the TSW process. Furthermore, integration of the HPU energy into the TSW stir rod can increase tool life of the stir rod, and can reduce shear forces to which the stir rod is subjected during the welding process. TSW has been used to successfully join 0.500-in (≈13-mm) thick commercially pure (CP) titanium, titanium 6AL- 4V, and titanium 6AL-4V ELI in weld joint lengths up to 9 ft (≈2.75-m) long. In addition, the TSW process was used to fabricate a sub-scale hexagonally shaped gun turret component for the U.S. Navy. The turret is comprised of six 0.5000-in (≈13-mm) thick angled welds. Each angled weld joint was prepared by machining the mating surfaces to 120deg. The angled weld joint was then fixtured using an upper and lower containment plate of the same geometry of the angled weld joint. The weld joint was then stirred by the stir rod as it and the upper and lower containment plates traverse through the angled joint prep.
Ding, Robert↗
TPSAS-NF1676L-13792-DND
Extreme structural requirements of future aerospace vehicles motivate the development of new, ultra-durable materials and game-changing methodologies for material certification and sustainment. Computational simulations spanning many orders of magnitude in length and time scales—from the nanoscale of underlying damage processes to the larger scales of continuum cracks—are being developed to support these requirements. Results of these simulations are used to deduce key aspects of material response to loads and environments, including: - The microstructural mechanics that govern metal fatigue crack initiation and growth - The variety and complexity of the dislocation-precipitate interac- tions that underpin plastic behavior and damage evolution - The energetic principles that govern the interaction of water with crack surfaces within a structural component - The mechanics of grain boundary separation Modeling the physics behind these metal fatigue behaviors is extremely complex, and requires intensive, high-fidelity simulations. The knowledge gained through these simulations, however, is forming the keystone for advanced material design and will enable development of more capable, reliable structures for aerospace vehicles.
Jacob Hochhalter↗
Seismic transducer measures small horizontal displacements
Pendular seismic transducer mounted on base plate measures small horizontal displacements of structures subjected to vibration where no fixed reference point is available. Enclosure of transducer in transparent plastic case prevents air currents from disturbing the pendulum balance.
Greenwood, T. L.↗
Delayed fracture in viscoelastic-plastic solids
Delayed fracture in viscoelastic-plastic solids - assessment of load carrying ability of glass-like polymers having potential applications as structural materials
Knauss, W. G.↗
Simplified method for nonlinear structural analysis
A simplified inelastic analysis computer program was developed for predicting the stress-strain history of a thermomechanically cycled structure from an elastic solution. The program uses an iterative and incremental procedure to estimate the plastic strains from the material stress-strain properties and a simulated plasticity hardening model. The simplified method was exercised on a number of problems involving uniaxial and multiaxial loading, isothermal and nonisothermal conditions, and different materials and plasticity models. Good agreement was found between these analytical results and nonlinear finite element solutions for these problems. The simplified analysis program used less than 1 percent of the CPU time required for a nonlinear finite element analysis.
Kaufman, A.↗
Development of a simplified procedure for cyclic structural analysis
Development was extended of a simplified inelastic analysis computer program (ANSYMP) for predicting the stress-strain history at the critical location of a thermomechanically cycled structure from an elastic solution. The program uses an iterative and incremental procedure to estimate the plastic strains from the material stress-strain properties and a plasticity hardening model. Creep effects can be calculated on the basis of stress relaxation at constant strain, creep at constant stress, or a combination of stress relaxation and creep accumulation. The simplified method was exercised on a number of problems involving uniaxial and multiaxial loading, isothermal and nonisothermal conditions, dwell times at various points in the cycles, different materials, and kinematic hardening. Good agreement was found between these analytical results and nonlinear finite-element solutions for these problems. The simplified analysis program used less than 1 percent of the CPU time required for a nonlinear finite-element analysis.
Kaufman, A.↗
Predicting the Cyclic Response of High-Temperature Materials
Simplified analytical procedure for estimating local stress/strain response in high-temperature structural component developed. Simplified procedure relies on assumption local inelastic response in hightemperature structure constrained by surrounding elastic material. Procedure assumes local response composed of elastic, time-independent plastic, and creep components. Conventional yield surface concept used to determine onset of plastic action.
Moreno, V.↗
Finite element analysis of structural components using viscoplastic models with application to a cowl lip problem
The viability of advanced viscoplastic models for nonlinear finite element analyses of structural components is investigated. Several uniaxial and a multiaxial problem are analyzed using the finite element implementation of Freed's viscoplastic model. Good agreement between the experimental and calculated uniaxial results validates the finite element implementation and gives confidence to apply it to more complex multiaxial problems. A comparison of results for a sample structural component (the cowl lip of a hypersonic engine inlet) with the earlier elastic, elastic-plastic, and elastic-plastic-creep analyses available in the literature shows that the elastic-viscoplastic analyses yield more reasonable stress and strain distributions. Finally, the versatility of the finite-element-based solution technology presented herein is demonstrated by applying it to another viscoplastic model.
Arya, V. K.↗
Understanding Friction Stir Welding
This Technical Memorandum explains the friction stir welding process in terms of two basic concepts: the concentration of deformation in a shear surface enveloping the tool and the composition of the overall plastic flow field around the tool from simple flow field components. It is demonstrated how weld structure may be understood and torque, drag, and lateral tool forces may be estimated using these concepts. Some discrepancies between computations and accompanying empirical data are discussed in the text. This work is intended to be helpful to engineers in diagnosing problems and advancing technology.
Nunes, A. C., Jr.↗
Tracking the Rates and Mechanisms of Canopy Damage and Recovery Following Hurricane Maria Using Multitemporal Lidar Data
Hurricane Maria, a Category 4 storm, snapped and uprooted canopy trees, removed large branches, and defoliated vegetation across Puerto Rico. The magnitude of forest damages and the rates and mechanisms of forest recovery following Maria provide important benchmarks for understanding the ecology of extreme events. We used airborne Lidar data acquired before (2017) and after Maria (2018, 2020) to quantify landscape-scale changes in forest structure along a 439-ha elevational gradient (100–800 m) in the Luquillo Experimental Forest. Damages from Maria were widespread, with 73% of the study area losing ≥ 1 m in canopy height (mean = −7.1 m). Taller forests at lower elevations suffered more damage than shorter forests above 600 m. Yet only 13.5% of the study area had canopy heights ≤ 2 m in 2018, a typical threshold for forest gaps, highlighting the importance of damaged trees and advanced regeneration on post-storm forest structure. Heterogeneous patterns of regrowth and recruitment yielded shorter and more open forests by 2020. Nearly 45% of forests experienced initial height loss > 1 m (2017–2018) followed by rapid height gain > 1 m (2018–2020), whereas 21.6% of forests with initial height losses showed little or no height gain, and 17.8% of forests exhibited no height changes larger than ± 1 m in either period. Canopy layers < 10 m tall accounted for most increases in canopy height and fractional cover between 2018 and 2020, with gains split evenly between height growth and lateral crown expansion by surviving individuals. These findings benchmark rates of gap formation, crown expansion, and canopy closure following hurricane damage and highlight the diversity of ecosystem impacts from heterogeneous spatial patterns and vertical stratification of forest regrowth following a major disturbance event.
forest structure↗
Tracking the Rates and Mechanisms of Canopy Damage and Recovery Following Hurricane Maria Using Multitemporal Lidar Data
Hurricane Maria, a Category 4 storm, snapped and uprooted canopy trees, removed large branches, and defoliated vegetation across Puerto Rico. The magnitude of forest damages and the rates and mechanisms of forest recovery following Maria provide important benchmarks for understanding the ecology of extreme events. We used airborne Lidar data acquired before (2017) and after Maria (2018, 2020) to quantify landscape-scale changes in forest structure along a 439-ha elevational gradient (100–800 m) in the Luquillo Experimental Forest. Damages from Maria were widespread, with 73% of the study area losing ≥ 1 m in canopy height (mean = −7.1 m). Taller forests at lower elevations suffered more damage than shorter forests above 600 m. Yet only 13.5% of the study area had canopy heights ≤ 2 m in 2018, a typical threshold for forest gaps, highlighting the importance of damaged trees and advanced regeneration on post-storm forest structure. Heterogeneous patterns of regrowth and recruitment yielded shorter and more open forests by 2020. Nearly 45% of forests experienced initial height loss > 1 m (2017–2018) followed by rapid height gain > 1 m (2018–2020), whereas 21.6% of forests with initial height losses showed little or no height gain, and 17.8% of forests exhibited no height changes larger than ± 1 m in either period. Canopy layers < 10 m tall accounted for most increases in canopy height and fractional cover between 2018 and 2020, with gains split evenly between height growth and lateral crown expansion by surviving individuals. These findings benchmark rates of gap formation, crown expansion, and canopy closure following hurricane damage and highlight the diversity of ecosystem impacts from heterogeneous spatial patterns and vertical stratification of forest regrowth following a major disturbance event.
forest structure↗
Viscoelasticity and plasticity considerations in the fracture of glasslike high polymers.
Fracture theory for amorphous high polymers below glass transition temperature, considering viscoelastic effects on structural defect stress concentration
CRACK PROPAGATION↗
High Temperature Structural Foam
The Aerospace Industry is experiencing growing demand for high performance polymer foam. The X-33 program needs structural foam insulation capable of retaining its strength over a wide range of environmental conditions. The High Speed Research Program has a need for low density core splice and potting materials. This paper reviews the state of the art in foam materials and describes experimental work to fabricate low density, high shear strength foam which can withstand temperatures from -220 C to 220 C. Commercially available polymer foams exhibit a wide range of physical properties. Some with densities as low as 0.066 g/cc are capable of co-curing at temperatures as high as 182 C. Rohacell foams can be resin transfer molded at temperatures up to 180 C. They have moduli of elasticity of 0.19 MPa, tensile strengths of 3.7 Mpa and compressive strengths of 3.6 MPa. The Rohacell foams cannot withstand liquid hydrogen temperatures, however Imi-Tech markets Solimide (trademark) foams which withstand temperatures from -250 C to 200 C, but they do not have the required structural integrity. The research activity at NASA Langley Research Center focuses on using chemical blowing agents to produce polyimide thermoplastic foams capable of meeting the above performance requirements. The combination of blowing agents that decompose at the minimum melt viscosity temperature together with plasticizers to lower the viscosity has been used to produce foams by both extrusion and oven heating. The foams produced exhibit good environmental stability while maintaining structural properties.
Weiser, Erik S.↗
An Improved Plastically Dilatant Unified Viscoplastic Constitutive Formulation for Multiscale Analysis of Polymer Matrix Composites Under High Strain Rate Loading
Polymer matrix composites are commonly used to fabricate energy-absorbing structures expected to experience impact loading. As such, a detailed understanding of the dynamic response of the constituent materials is necessary. Since the rate, temperature, and pressure dependence of carbon fiber reinforced polymer matrix composites are primarily manifestations of the rate, temperature, and pressure dependence of the polymer matrix, it is crucial that the constitutive behavior of the matrix be accurately characterized. In this work, an existing unified viscoplastic constitutive formulation is extended to ensure thermodynamic consistency and to more accurately account for the tension-compression asymmetry observed in the response of polymeric materials. A new plastic potential function is proposed, and elementary loading conditions are utilized to determine relations between model constants to ensure nonnegative plastic dissipation, a necessary thermodynamic requirement. Expressions for plastic Poisson’s ratios are derived and are bounded by enforcing nonnegative plastic dissipation. The model is calibrated against available experimental data from tests conducted over a range of strain rates, temperatures, and loading cases on a representative thermoset epoxy; good correlation between simulations and experimental data is obtained. Temperature rises due to the conversion of plastic work to heat are computed via the adiabatic heat energy equation. The viscoplastic polymer model is then used as a constitutive model in the generalized method of cells micromechanics theory to investigate the effects of matrix adiabatic heating on the high strain rate response of a unidirectional composite. The thermodynamic consistency of the model ensures plastic dissipation can only cause an increase in temperature. Simulation results indicate that significant thermal softening due to the conversion of plastic work to heat is observed in the composite for matrix dominated deformation modes.
Impact loading↗
Structural basis of transcription: RNA polymerase II substrate binding and metal coordination using a free-electron laser
Catalysis and translocation of multisubunit DNA-directed RNA polymerases underlie all cellular mRNA synthesis. RNA polymerase II (Pol II) synthesizes eukaryotic pre-mRNAs from a DNA template strand buried in its active site. Structural details of catalysis at near-atomic resolution and precise arrangement of key active site components have been elusive. Here, we present the free-electron laser (FEL) structures of a matched ATP-bound Pol II and the hyperactive Rpb1 T834P bridge helix (BH) mutant at the highest resolution to date. The radiation-damage-free FEL structures reveal the full active site interaction network, including the trigger loop (TL) in the closed conformation, bonafide occupancy of both site A and B Mg 2+ , and, more importantly, a putative third (site C) Mg 2+ analogous to that described for some DNA polymerases but not observed previously for cellular RNA polymerases. Molecular dynamics (MD) simulations of the structures indicate that the third Mg 2+ is coordinated and stabilized at its observed position. TL residues provide half of the substrate binding pocket while multiple TL/BH interactions induce conformational changes that could allow translocation upon substrate hydrolysis. Consistent with TL/BH communication, a FEL structure and MD simulations of the T834P mutant reveal rearrangement of some active site interactions supporting potential plasticity in active site function and long-distance effects on both the width of the central channel and TL conformation, likely underlying its increased elongation rate at the expense of fidelity.
Science & Technology - Other Topics↗
Laminated anisotropic reinforced plastic plates and shells
Basic technical theories and engineering calculation equations for anisotropic plates and shells made of rigid reinforced plastics, mainly laminated fiberglass, are presented and discussed. Solutions are given for many problems of design of structural plates and shells, including curved sections and tanks, as well as two chapters on selection of the optimum materials, are given. Accounting for interlayer shearing and transverse separation, which are new engineering properties, are discussed. Application of the results obtained to thin three ply plates and shells wth a light elastic filler is presented and discussed.
Korolev, V. I.↗