A photoelastic investigation of stress wave loading of a crack
Crack wave loading, investigating dynamic stress intensity factor and time response with photoelastic technique
Smith, D. G.↗
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Investigation of Structural Factors of Safety for the Space Shuttle
A study was made of the factors governing the structural design of the fully reusable space shuttle booster to establish a rational approach to select optimum structural factors of safety. The study included trade studies of structural factors of safety versus booster service life, weight, cost, and reliability. Similar trade studies can be made on other vehicles using the procedures developed. The major structural components of a selected baseline booster were studied in depth, each being examined to determine the fatigue life, safe-life, and fail-safe capabilities of the baseline design. Each component was further examined to determine its reliability and safety requirements, and the change of structural weight with factors of safety. The apparent factors of safety resulting from fatigue, safe-life, proof test, and fail-safe requirements were identified. The feasibility of reduced factors of safety for design loads such as engine thrust, which are well defined, was examined.
Source record↗
Premium quality 5A1-2.5 Sn ELI titanium production
Preliminary design and reliability analysis conducted on the turbopump for the NERVA 75,000 full flow cycle engine, indicated that the turbopump bearings were the most critical turbopump parts in meeting the 10 hour life at the required turbopump reliability of .99978. The analysis revealed that significant reductions (approximately a factor of 3.25) in bearing loads would be achieved by fabricating the rotating parts from titanium in lieu of A286 or 718. This is basically due to the difference in density of the materials and the resulting mass effect on the location of the first and second stick mode critical speeds. For the selected rotor configuration, the lighter material has a first critical speed at approximately 36,000 rpm, while that of the heavier material has a first critical at approximately 27,000 rpm. As the operating range of the turbopump is from 0 to 30,000 rpm, the heavier material would have a stick mode critical in the operating range.
Dessau, P. P.↗
Selection of appropriate test method for simulating steady-state spacecraft launch loads
In ground testing prior to launch the static loads portion of the launch profile may be simulated by either applying static loads directly to the spacecraft through an appropriate loading facility or by subjecting the spacecraft to acceleration loads on a centrifuge. The factors to be considered in selecting one of the two simulation methods are discussed, giving attention to the relative advantages of the two methods in each case.
Shockey, E. F.↗
Finite element stress analysis of a notched coupon specimen for in-plane shear behaviour of composites
The results of a linear elastic, plane stress finite element investigation of the stress distribution in a double V-notched coupon specimen are presented for an isotropic material (steel) and five graphite/polyimide laminates: (0), (90), (0/90)s, (plus or minus 45)s and (0/90/plus or minus 45)s. Stress contours, stress profiles, and stress concentration factors are presented for specimens loaded through rigid fixtures. It is shown that the finite element analysis predicts a region of essentially uniform pure shear in the central portion of the specimen for all laminates considered. Stress concentrations vary considerably with laminate configuration. The influences of elastic fixtures and thermal stresses on the stress distribution in (0) laminates are also investigated. The (0) laminate is predicted to exhibit maximum pure shear in the center of the test section for both rigid and elastic fixtures. It is concluded that the specimen is a practicable candidate for use as a composite shear specimen.
Herakovich, C. T.↗
A crack opening stress equation for fatigue crack growth
A general crack opening stress equation is presented which may be used to correlate crack growth rate data for various materials and thicknesses, under constant amplitude loading, once the proper constraint factor has been determined. The constraint factor, alpha, is a constraint on tensile yielding; the material yields when the stress is equal to the product of alpha and sigma. Delta-K (LEFM) is plotted against rate for 2024-T3 aluminum alloy specimens 2.3 mm thick at various stress ratios. Delta-K sub eff was plotted against rate for the same data with alpha = 1.8; the rates correlate well within a factor of two.
Newman, J. C., Jr.↗
The aerodynamic challenges of SRB recovery
Recovery and reuse of the Space Shuttle solid rocket boosters was baselined to support the primary goal to develop a low cost space transportation system. The recovery system required for the 170,000-lb boosters was for the largest and heaviest object yet to be retrieved from exoatmospheric conditions. State-of-the-art design procedures were ground-ruled and development testing minimized to produce both a reliable and cost effective system. The ability to utilize the inherent drag of the boosters during the initial phase of reentry was a key factor in minimizing the parachute loads, size and weight. A wind tunnel test program was devised to enable the accurate prediction of booster aerodynamic characteristics. Concurrently, wind tunnel, rocket sled and air drop tests were performed to develop and verify the performance of the parachute decelerator subsystem. Aerodynamic problems encountered during the overall recovery system development and the respective solutions are emphasized.
Bacchus, D. L.↗
Elastic-plastic stress concentrations around crack-like notches in continuous fiber reinforced metal matrix composites
Continuous fiber silicon-carbide/aluminum composite laminates with slits were tested statically to failure. Five different layups were examined: (0) sub 8, (0 sub 2/ + or - 45) sub s, (0/90) sub 2s), (0/ + or - 45/90 sub s), and (+ or - 45) sub 2s. Either a 9.5 or a 19 mm slit was machined in the center of each specimen. The strain distribution ahead of the slit tip was found experimentally with a series of strain gages bonded ahead of the slit tip. A three-dimensional finite element program (PAFAC) was used to predict the strain distribution ahead of the slit tip for several layups. For all layups, except the (0) sub 8, the yielding of the metal matrix caused the fiber stress concentration factor to increase with increasing load. This is contrary to the behavior seen in homogeneous materials where yielding causes the stress concentration to drop. For the (0) sub 8 laminate, yielding of the matrix caused a decrease in the fiber stress concentration. The finite element analysis predicted these trends correctly.
Johnson, W. S.↗
Expansion of epicyclic gear dynamic analysis program
The multiple mesh/single stage dynamics program is a gear tooth analysis program which determines detailed geometry, dynamic loads, stresses, and surface damage factors. The program can analyze a variety of both epicyclic and single mesh systems with spur or helical gear teeth including internal, external, and buttress tooth forms. The modifications refine the options for the flexible carrier and flexible ring gear rim and adds three options: a floating Sun gear option; a natural frequency option; and a finite element compliance formulation for helical gear teeth. The option for a floating Sun incorporates two additional degrees of freedom at the Sun center. The natural frequency option evaluates the frequencies of planetary, star, or differential systems as well as the effect of additional springs at the Sun center and those due to a flexible carrier and/or ring gear rim. The helical tooth pair finite element calculated compliance is obtained from an automated element breakup of the helical teeth and then is used with the basic gear dynamic solution and stress postprocessing routines. The flexible carrier or ring gear rim option for planetary and star spur gear systems allows the output torque per carrier and ring gear rim segment to vary based on the dynamic response of the entire system, while the total output torque remains constant.
Boyd, Linda Smith↗
Probabilistic finite elements for fracture mechanics
The probabilistic finite element method (PFEM) is developed for probabilistic fracture mechanics (PFM). A finite element which has the near crack-tip singular strain embedded in the element is used. Probabilistic distributions, such as expectation, covariance and correlation stress intensity factors, are calculated for random load, random material and random crack length. The method is computationally quite efficient and can be expected to determine the probability of fracture or reliability.
Besterfield, Glen↗
Elastic-plastic stress concentrations around crack-like notches in continuous fiber reinforced metal matrix composites
Continuous fiber silicon-carbide/aluminum composite laminates with slits were tested statically to failure. Five different layups were examined: (0) sub 8, (0 sub 2/ + or - 45) sub s, (0/90) sub 2s), (0/ + or - 45/90 sub s), and (+ or - 45) sub 2s. Either a 9.5 or a 19 mm slit was machined in the center of each specimen. The strain distribution ahead of the slit tip was found experimentally with a series of strain gages bonded ahead of the slit tip. A three-dimensional finite element program (PAFAC) was used to predict the strain distribution ahead of the slit tip for several layups. For all layups, except the (0) sub 8, the yielding of the metal matrix caused the fiber stress concentration factor to increase with increasing load. This is contrary to the behavior seen in homogeneous materials where yielding causes the stress concentration to drop. For the (0) sub 8 laminate, yielding of the matrix caused a decrease in the fiber stress concentration. The finite element analysis predicted these trends correctly.
Johnson, W. S.↗
Nonlinear and distributed parameter models of the mini-mast truss
Large spacecraft such as Space Station Freedom employ large trusses in their construction. The structural dynamics of such trusses often exhibit nonlinear behavior and little damping which can impact significantly the performance of control systems. The Mini-MAST truss was constructed to research such structural dynamics and control systems. The Mini-MAST truss is an object of study for the guest investigator program as part of NASA's controls-structures interaction program. The Mini-MAST truss is deployable and about 65 ft long. Although the bending characteristics of the Mini-MAST truss are essentially linear, the angular deflection under torsional loading has exhibited significant hysteresis and nonlinear stiffness. It is the purpose to develop nonlinear and distributed parameter models of the truss and to compare the model dynamics with actual measurements. Distributed parameter models have the advantage of requiring fewer model parameters. A tangent function is used to describe the nonlinear stiffness in torsion, partly because of the convenience of its easily expressed inverse. Hysteretic slip elements are introduced and extended to a continuum to account for the observed hysteresis in torsion. The contribution of slipping to the structural damping is analyzed and found to be strongly dependent on the applied loads. Because of the many factors which affect the damping and stiffness in a truss, it is risky to assume linearity.
Taylor, Lawrence W., Jr.↗
Microstructure: Property correlation
Strain controlled torsional and biaxial (tension-torsion) low cycle fatigue behavior of Waspaloy was studied at room temperature as a function of heat treatment. Biaxial tests were conducted under proportional (when the axial and torsional strain cycles are in-phase) and non-proportional (when the axial and torsional strain cycles are 90 deg out-of-phase) cyclic conditions. The deformation behavior under these different cyclic conditions were evaluated by slip trace analysis. For this, a Schmidt-type factor was defined for multiaxial loading conditions and it was shown that when the slip deformation is predominant, non-proportional cycles are more damaging than proportional or pure axial or torsional cycles. This was attributed to the fact that under non-proportional cyclic conditions, deformation was through multiple slip as opposed single slip for other loading conditions, which gave rise to increased hardening. The total life for a given test condition was found to be independent of heat treatment. This was interpreted as being due to the differences in the cycles to initiation and propagation of cracks.
Jayaraman, N.↗
Torsional and biaxial (tension-torsion) fatigue damage mechanisms in Waspaloy at room temperature
Strain controlled torsional and biaxial (tension-torsion) low cycle fatigue behavior of Waspaloy was studied at room temperature as a function of heat treatment. Biaxial tests were conducted under proportional and nonproportional cyclic conditions. The deformation behavior under these different cyclic conditions was evaluated by slip trace analysis. For this, a Schmidt-type factor was defined for multiaxial loading conditions, and it was shown that when the slip deformation is predominant, nonproportional cycles are more damaging than proportional or pure axial or torsional cycles. This was attributed to the fact that under nonproportional cyclic conditions, deformation was through multiple slip, as opposed to single slip for other loading conditions, which gave rise to increased hardening. The total life for a given test condition was found to be independent of heat treatment. This was interpreted as being due to the differences in the cycles to initiation and propagation of cracks.
Jayaraman, N.↗
Dynamic response of a hammerhead launch vehicle wind-tunnel model
A wind-tunnel test of a 1/10th-scale Atlas-Centaur I large payload fairing launch vehicle model was conducted in the NASA Langley Transonic Dynamics Tunnel. The wind tunnel model was an aeroelastically-scaled version of the flight vehicle and was capable of simulating either of the first two bending vibration modes of the full-scale vehicle by a partial mode technique. The primary purpose of the test was to gather data concerning buffet response which could be used to clear the vehicle for flight. Additionally, angle-of-attack studies were conducted and several payload fairing configurations were tested to assess the buffet response and dynamic stability of off-design flight conditions and geometric parameters. No dynamic instabilities were found for any of the configurations tested. The buffet response data for the nominal flight configuration indicate that the unsteady buffet loads represent 5 to 10 percent of the total design load; therefore, the buffet loads are not a large factor affecting the overall vehicle design. Payload fairing length-to-diameter ratio variations were found to have small effects on the buffet response of the model, except in the case of the smallest length-to-diameter models for the second bending mode simulation. The effects of angle of attack on buffet response were found to be small. The model was more sensitive to Mach number changes than to angle of attack. The buffet response results from this wind tunnel test were influenced by the tunnel facility vibration levels. An attempt was made to experimentally reduce the effect of the facility mechanical vibration for the nominal flight configuration by testing with vertical rods used to stiffen the sting support. The first flight of the Atlas-Centaur I vehicle successfully occurred on July 25, 1990, and a comparison of flight measurements with wind tunnel data is presented. The flight data was found to be well within the 3 sigma level of the wind tunnel data.
Cole, Stanley R.↗
Extrinsic factors in the mechanics of bridged cracks
The far-reaching effects of such extrinsic factors as specimen shape and load distribution on bridged crack propagation, in cases where bridging-zone length is comparable to any of the crack and/or specimen dimensions, are presently demonstrated in view of calculation results for single-edge-notch specimens under uniform remote tension. The inherent risk of nonconservative predictions or reliability and strength may be reduced by considering the relationship between the bridging tractions and the crack-opening displacement as a fundamental material property. The fundamentality of the 'bridging length scale', or initial crack extension over which the bridging zone matures, is demonstrated.
Cox, B. N.↗
Long term integrity for space station power systems
A study was made of the High Temperature Design Codes ASME N47, British R5, and the French RCC-MR Rules. It is concluded that all these codes provide a good basis of design for space application. The new British R5 is the most complete since it deals with the problem of defects. The ASME N47 was subjected longer to practical application and scrutiny. A draft code is introduced, and a proposed draft for high temperature design in which attempts were made to identify gaps and improvements is suggested. The design is limited by creep characteristics. In these circumstances, life is strongly affected by the selected value of the factor of safety. The factor of safety of primary loads adopted in the codes is 1.5. Maybe a lower value of 1.25 is permissible for use in space. Long term creep rupture data for HAYNES 188 is deficient and it is suggested that extrapolation methods be investigated.
Leckie, F. A.↗
Research needs for a commercial passenger tiltrotor
The National Aeronautics and Space Administration (NASA) recently completed a series of contracts and studies that examined the technology needs for a tiltrotor aircraft in commercial service as well as military missions. The commercial needs arise out of market-driven requirements that include vertiport location and design, passenger comfort levels and competitive costs. The military needs are derived from time-sensitive missions and combat effectiveness. In response to these results, NASA has decided to address the commercial needs first, recognizing that there will be eventual payoff to military missions as well. Research goals were explored in acoustics, flight dynamics, human factors and displays, dynamics and loads, propulsion, safety, and configuration design. The paper describes the development of these goals from the market requirements and the implications for possible research activities. The aircraft issues that were addressed include number of blades, advanced blade planforms, steep approach requirements and pilot-cockpit interface for civil operations.
Unger, George↗