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NASA NTRS2020

Residual Stress Measurements of Ni-base Superalloys through Neutron Diffraction

Linear friction welding (LFW) is being considered for joining single crystal to polycrystalline nickel-base alloys for advanced high temperature gas turbine disks. Unfortunately, the transient thermal cycle during the welding generates undesirable residual stresses. Additionally, upon thermal treatment to relieve these residual stresses the weld joints often crack. To understand this issue, state-of-the-art neutron diffraction was performed near weld joints to quantify the residual stresses created by varying linear friction weld conditions. The residual stresses were measured along three orthogonal axes in both the polycrystalline LSHR and single crystal SC-180 alloys. Residual stress measurements using a contour method were used to compare the calculations obtained by neutron diffraction. The results suggest high residual stresses can be successfully reduced using both pre- and post-weld processing steps. Moreover, the effect of grain size and pre-heat temperatures on the LFW process were explored.

Superalloys↗

NASA NTRSDate not supplied

Formation of Insoluble Organic Material from the Ultraviolet Irradiation of Laboratory Ice Photolysis Residues

We present preliminary results from the study of ice photolysis residues which were exposed to ultraviolet (UV)/extreme UV (EUV) photon radiation. The residues were produced from the simultaneous deposition and UV irradiation of ice mixtures of astrophysical interest (H2O, CH3OH, CO, NH3, without/with N2 and/or O2, and without/with small quantities of aromatic compounds) at 15–20 K using an H2 lamp, which emits 10.2-eV (121.6 nm) Lyman-α photons and a continuum at 7.5–8 eV (155–165 nm). After warm-up to room temperature and subsequent sublimation of volatile compounds, the refractory materials (residues) recovered at room temperature were analyzed with infrared (IR) microscopy and then further irradiated with UV/EUV photons at a synchrotron facility, on a beamline providing a broad-band photon beam in the 4–45-eV range with a ~1016 photons s-1 flux.2 The residues were UV/EUV irradiated with increasing photon doses ranging from ~1018 to ~1021 photons, i.e., covering 4 orders of magnitude and relevant to those experienced by ice-coated grains in the protosolar nebula.1. After UV/EUV irradiation, residues were analyzed with IR microscopy and the data compared to those before irradiation to identify changes in chemical composition as a function of the photon dose. UV/EUV-irradiated residues were also analyzed with other techniques such as nanoscale secondary-ion mass spectrometry (nanoSIMS) to the study the changes in isotopic composition, and scanning transmission electron microscopy to look at variations in structure and C bonding distribution. Results will be compared with data from extraterrestrial materials, in particular, meteoritic insoluble organic material (IOM) and interplanetary dust particles (IDPs).

Ices↗

NASA NTRSDate not supplied

RESIDUAL DEFORMATION ANALYSIS IN COMPOSITE SHELL STRUCTURES MANUFACTURED USING AUTOMATED FIBER PLACEMENT

The manufacturing of composites typically produces residual stresses that can significantly affect the final shape of the structure. The process of automated fiber placement (AFP) has become a prominent manufacturing technique in developing layups with tailored, variable stiffness morphology. The steered patterns of fiber tows with and without overlaps produce residual deformations that are distinctive from traditional layups. Digital image correlation was used to measure the AFP lamina coefficients of thermal expansion, which were incorporated into finite element analyses (FEA) to model the cooling phase of the cure cycle. The effects of nonlinear analysis and temperature-dependent lamina properties calculated using self-consistent field micromechanics, on the resulting residual deformation of shells, were also modeled. The predicted residual deformation was analyzed by considering out-of-roundness in cylindrical shells and compared to the experimental results. The shell FEA results were well-correlated with the overall deformed shape of the AFP cylinder with overlaps, while the shell FEA model of the AFP cylinder without overlaps did not show as good of qualitative match of the deformation pattern. Analytical correlation with measured results were insensitive to material softening at elevated temperatures, geometric nonlinearities, and variations in measured lamina thermal properties. To improve the accuracy of the residual deformation analysis, these results suggest that the thermo-chemical shrinkages preceding the cooldown should be considered, as well as possible variations in ply level microstructure due to the presence of the embedded fiber tow gaps and overlaps.

Composites↗

NASA NTRSDate not supplied

Geometric Sensitivity of Residual Fields in Metal Additive Manufacturing

The sensitivity of geometrical parameters on the residual stress and distortion as computed by a metal additive manufacturing simulation is presented. A nozzle-like geometry was chosen with its length, wall thickness, and outer radius varied. A Latin hypercube sampling of 300 specimens produced the combinations of the geometrical parameters. Full thermomechanical simulations predicted the residual fields. Statistical analysis including regression curves shows that there is a strong correlation between these residual fields and the geometry, hinting that it may be possible to predictably influence the residual displacements and residual stresses by varying the overall geometry.

Multiscale Modeling↗

NASA NTRS1973

Residual stress alleviation of aircraft metal structures reinforced with filamentary composites

Methods to eliminate or reduce residual stresses in aircraft metal structures reinforced by filamentary composites are discussed. Residual stress level reductions were achieved by modifying the manufacturing procedures used during adhesive bonding. The residual stress alleviation techniques involved various forms of mechanical constraint which were applied to the components during bonding. Nine methods were evaluated, covering a wide range in complexity. All methods investigated during the program affected the residual stress level. In general, residual stresses were reduced by 70 percent or more from the stress level produced by conventional adhesive bonding procedures.

Kelly, J. B.↗

NASA NTRS1980

Smoke characteristics of distillate and residual fuel burning in gas turbine combustors

During the development of a rich-lean staged dry low NOx combustor, the conventional trend of increasing smoke with increasing operating equivalence ratio was found when tests were run with distillate fuel (% H = 13.0). However, when tests were run with residual fuel (% H = 11.4), the trend was reversed. In addition, when the same combustor was run with blends of distillate fuel and residual fuel, a drastic improvement of smoke was observed when only 6 percent of residual fuel was mixed with distillate fuel, and for any blending of more than 10 percent of residual fuel the combustor was practically smoke free. A chemical analysis of fuel samples revealed an appreciable amount of trace metals in the residual fuel, giving rise to the suspicion that the smoke reduction may have been due in part to these trace metals. Of these elements found, vanadium is believed to be the most likely to cause smoke reduction because of its relatively high concentration.

Liu, T. M.↗

NASA NTRS1982

Gravity and geoid anomalies of the Philippine Sea: Evidence on the depth of compensation for the negative residual water depth anomaly

A negative free-air gravity anomaly which occurs in the central part of the Philippine Sea was examined to determine the distribution and nature of possible regional mass excesses or deficiencies. Geoid anomalies from GEOS-3 observation were positive. A negative residual geoid anomaly consistent with the area of negative free-air gravity anomalies were found. Theoretical gravity-topography and geoid-topography admittance functions indicated that high density mantle at about 60 km dept could account for the magnitudes of the gravity and residual geoid anomaly and the 1 km residual water depth anomaly in the Philippine Sea. The negative residual depth anomaly may be compensated for by excess density in the uppermost mantle, but the residual geoid and regional free-air gravity anomalies and a slow surface wave velocity structure might result from low-density warm upper mantle material lying beneath the zone of high-density uppermost mantle. From a horizontal disk approximation, the depth of the low-density warm mantle was estimated to be on the order of 200 km.

Bowin, C.↗

NASA NTRS1989

Effects of fatigue and environment on residual strengths of center-cracked graphite/epoxy buffer strip panels

The effects of fatigue, moisture conditioning, and heating on the residual tension strengths of center-cracked graphite/epoxy buffer strip panels were evaluated using specimens made with T300/5208 graphite epoxy in a 16-ply quasi-isotropic layup, with two different buffer strip materials, Kevlar-49 or S-glass. It was found that, for panels subjected to fatigue loading, the residual strengths were not significantly affected by the fatigue loading, the number of repetitions of the loading spectrum, or the maximum strain level. The moisture conditioning reduced the residual strengths of the S-glass buffer strip panels by 10 to 15 percent below the ambient results, but increased the residual strengths of the Kevlar-49 buffer strip panels slightly. For both buffer strip materials, the heat increased the residual strengths of the buffer strip panels slightly over the ambient results.

Bigelow, Catherine A.↗

NASA NTRS1989

X-ray diffraction measurements of residual stresses in SiC/Ti composites

Residual stresses are developed in metal matrix composites during consolidation because of the difference in the coefficient of thermal expansion of the fiber and matrix constituents. X-ray diffraction techniques were used to measure tensile residual stresses in the matrix component of two different titanium alloy composites reinforced with continuous silicon carbide fibers. The titanium alloy matrices were a beta-stabilized alloy Ti-15V-3Al-3Cr-3Sn, and an ordered multiphase (alpha + beta) alloy, Ti-14Al-21Nb. Residual tensile stresses as high as 62 percent of the yield of Ti-15V-3Al-3Cr-3Sn and 70 percent of the yield of Ti-14Al-21Nb were measured in the longitudinal direction on unidirectionally reinforced composites. By measuring residual stresses in four different composite lay-ups, the composite lay-up was determined to have a significant effect on the residual stress state near the surface.

Brown, K. M.↗

NASA NTRS1992

Scanning electron microscope/energy dispersive x ray analysis of impact residues on LDEF tray clamps

To better understand the nature of particulates in low-Earth orbit (LEO), and their effects on spacecraft hardware, we are analyzing residues found in impacts on the Long Duration Exposure Facility (LDEF) tray clamps. LDEF experiment trays were held in place by 6 to 8 chromic-anodized aluminum (6061-T6) clamps that were fastened to the spacecraft frame using three stainless steel hex bolts. Each clamp exposed an area of approximately 58 sq cm (4.8 cm x 12.7 cm x .45 cm, minus the bolt coverage). Some 337 out of 774 LDEF tray clamps were archived at JSC and are available through the Meteoroid & Debris Special Investigation Group (M&D SIG). Optical scanning of clamps, starting with Bay/Row A01 and working toward H25, is being conducted at JSC to locate and document impacts as small as 40 microns. These impacts are then inspected by Scanning Electron Microscopy/Energy Dispersive X-ray Analysis (SEM/EDXA) to select those features which contain appreciable impact residue material. Based upon the composition of projectile remnants, and using criteria developed at JSC, we have made a preliminary discrimination between micrometeoroid and space debris residue-containing impact features. Presently, 13 impacts containing significant amounts of unmelted and semi-melted micrometeoritic residues were forwarded to Centre National d'Etudes Spatiales (CNES) in France. At the CNES facilities, the upgraded impacts were analyzed using a JEOL T330A SEM equipped with a NORAN Instruments, Voyager X-ray Analyzer. All residues were quantitatively characterized by composition (including oxygen and carbon) to help understand interplanetary dust as possibly being derived from comets and asteroids.

Bernhard, Ronald P.↗

NASA NTRS1995

Analytical electron microscopy of LDEF impactor residues

The LDEF contained 57 individual experiment trays or tray portions specifically designed to characterize critical aspects of meteoroid and debris environment in low-Earth orbit (LEO). However, it was realized from the beginning that the most efficient use of the satellite would be to characterize impact features from the entire surface of the LDEF. With this in mind particular interest has focused on common materials facing in all 26 LDEF facing directions; among the most important of these materials has been the tray clamps. Therefore, in an effort to better understand the nature and flux of particulates in LEO, and their effects on spacecraft hardware, we are analyzing residues found in impact features on LDEF tray clamp surfaces. This paper summarizes all data from 79 clamps located on Bay A & B of the LDEF. We also describe current efforts to characterize impactor residues recovered from the impact craters, and we have found that a low, but significant, fraction of these residues have survived in a largely unmelted state. These residues can be characterized sufficiently to permit resolution of the impactor origin. We have concentrated on the residue from chondritic interplanetary dust particles (micrometeoroids), as these represent the harshest test of our analytical capabilities.

Bernhard, Ronald P.↗

NASA NTRS1992

Compressive residual strength of graphite/epoxy laminates after impact

The issue of damage tolerance after impact, in terms of the compressive residual strength, was experimentally examined in graphite/epoxy laminates using Hercules AS4/3501-6 in a (+ or - 45/0)(sub 2S) configuration. Three different impactor masses were used at various velocities and the resultant damage measured via a number of nondestructive and destructive techniques. Specimens were then tested to failure under uniaxial compression. The results clearly show that a minimum compressive residual strength exists which is below the open hole strength for a hole of the same diameter as the impactor. Increases in velocity beyond the point of minimum strength cause a difference in the damage produced and cause a resultant increase in the compressive residual strength which asymptotes to the open hole strength value. Furthermore, the results show that this minimum compressive residual strength value is independent of the impactor mass used and is only dependent upon the damage present in the impacted specimen which is the same for the three impactor mass cases. A full 3-D representation of the damage is obtained through the various techniques. Only this 3-D representation can properly characterize the damage state that causes the resultant residual strength. Assessment of the state-of-the-art in predictive analysis capabilities shows a need to further develop techniques based on the 3-D damage state that exists. In addition, the need for damage 'metrics' is clearly indicated.

Guy, Teresa A.↗

NASA NTRS1996

Conditional Entropy-Constrained Residual VQ with Application to Image Coding

This paper introduces an extension of entropy-constrained residual vector quantization (VQ) where intervector dependencies are exploited. The method, which we call conditional entropy-constrained residual VQ, employs a high-order entropy conditioning strategy that captures local information in the neighboring vectors. When applied to coding images, the proposed method is shown to achieve better rate-distortion performance than that of entropy-constrained residual vector quantization with less computational complexity and lower memory requirements. Moreover, it can be designed to support progressive transmission in a natural way. It is also shown to outperform some of the best predictive and finite-state VQ techniques reported in the literature. This is due partly to the joint optimization between the residual vector quantizer and a high-order conditional entropy coder as well as the efficiency of the multistage residual VQ structure and the dynamic nature of the prediction.

Kossentini, Faouzi↗

NASA NTRS1997

Factors Influencing Residual Stresses in Yttria Stabilized Zirconia Thermal Barrier Coatings

To improve gas turbine and diesel engine performance using thermal barrier coatings (TBC's) requires an understanding of the factors that influence the in-service behavior of thermal barrier coatings. One of the many factors related to coating performance is the state of stress in the coating. The total stress state is composed of the stresses due to the in-service loading history and the residual stresses. Residual stresses have been shown to affect TBC life, the bond strength of thermal spray coatings, and the fatigue life of tungsten carbide coatings. Residual stresses are first introduced in TBC's by the spraying process due to elevated temperatures during processing and the difference in coefficients of thermal expansion of the top coat, bond coat, and substrate. Later, the residual stresses can be changed by the in-service temperature history due to a number of time and temperature dependent mechanisms, such as oxidation, creep, and sintering. Silica content has also been shown to affect sintering and the cyclic life of thermal barrier coatings. Thus, it is important to understand how the spraying process, the in-service thermal cycles, and the silica content can create and alter residual stresses in thermal barrier coatings.

McGrann, Roy T. R.↗

NASA NTRS1997

Determination of Residual Stress in Composite Materials Using Ultrasonic Waves

The performance of high temperature composites can be significantly affected by the presence of residual stresses. These stresses arise during cooling processes from fabrication to room temperature due to mismatch of thermal expansion coefficients between matrix and fiber materials. This effect is especially pronounced in metal matrix and intermetallic composites. It can lead to plastic deformations, matrix cracking and fiber/matrix interface debonding. In this work the feasibility of ultrasonic techniques for residual stress assessment in composites is addressed. A novel technique for absolute stress determination in orthotropic materials from angular dependencies of ultrasonic velocities is described. The technique is applicable for determination of both applied and residual stresses and does not require calibration measurements on a reference sample. The important advantage of this method is that stress is determined simultaneously with stress-dependent elastic constants and is thus decoupled from the material texture. It is demonstrated that when the principal plane stress directions coincide with acoustical axes, the angular velocity data in the plane perpendicular to the stress plane may be used to determine both stress components. When the stress is off the acoustical axes, the shear and the difference of the normal stress components may be determined from the angular dependence of group velocities in the plane of stresses. Synthetic sets of experimental data corresponding to materials with different anisotropy and stress levels are used to check the applicability of the technique. The method is also verified experimentally. A high precision ultrasonic wave transmission technique is developed to measure angular dependence of ultrasonic velocities. Examples of stress determination from experimental velocity data are given. A method is presented for determination of velocities of ultrasonic waves propagating through the composite material with residual stresses. It is based on the generalized self-consistent multiple scattering model. Calculation results for longitudinal and shear ultrasonic wave velocities propagating perpendicular to the fibers direction in SCS-6/Ti composite with and without residual stresses are presented. They show that velocity changes due to presence of stresses are of order 1%.

Rokhlin, S. I.↗

NASA NTRS1997

Effects of Bioreactor Retention Time on Aerobic Microbial Decomposition of CELSS Crop Residues

The focus of resource recovery research at the KSC-CELSS Breadboard Project has been the evaluation of microbiologically mediated biodegradation of crop residues by manipulation of bioreactor process and environmental variables. We will present results from over 3 years of studies that used laboratory- and breadboard-scale (8 and 120 L working volumes, respectively) aerobic, fed-batch, continuous stirred tank reactors (CSTR) for recovery of carbon and minerals from breadboard grown wheat and white potato residues. The paper will focus on the effects of a key process variable, bioreactor retention time, on response variables indicative of bioreactor performance. The goal is to determine the shortest retention time that is feasible for processing CELSS crop residues, thereby reducing bioreactor volume and weight requirements. Pushing the lower limits of bioreactor retention times will provide useful data for engineers who need to compare biological and physicochemical components. Bioreactor retention times were manipulated to range between 0.25 and 48 days. Results indicate that increases in retention time lead to a 4-fold increase in crop residue biodegradation, as measured by both dry weight losses and CO2 production. A similar overall trend was also observed for crop residue fiber (cellulose and hemicellulose), with a noticeable jump in cellulose degradation between the 5.3 day and 10.7 day retention times. Water-soluble organic compounds (measured as soluble TOC) were appreciably reduced by more than 4-fold at all retention times tested. Results from a study of even shorter retention times (down to 0.25 days), in progress, will also be presented.

Strayer, R. F.↗

NASA NTRS1961

Residual Static Strength of ALuminum-Alloy Beams Containing Fatigue Cracks in the Tension Covers

Static tests were performed on 31 box beams containing fatigue cracks in order to determine their residual static strengths. The beams were constructed of 7075 and 2024 aluminum alloy according to several designs and employed stringers that were either bonded, riveted, or an integral part of the skin. skin (both aaterials) had the highest residual static strengths, whereas 7075 beams with integrally stiffened covers had the lowest residual static strengths. Except for the integrally stiffened beams, the skin material did not contribute to the residual static strength of the beams because the crack propagated across the skin before maximum load was reached. For the integrally stiffened beams, crack propagation and failure were synonymous. The test results are compared with predictions of the residual static strength. Fair agreement between predicted strength and actual strength was obtained for all beams tested.

Leybold, Herbert A.↗

NASA NTRS2002

Properties of the Residual Stress of the Temporally Filtered Navier-Stokes Equations

The development of a unifying framework among direct numerical simulations, large-eddy simulations, and statistically averaged formulations of the Navier-Stokes equations, is of current interest. Toward that goal, the properties of the residual (subgrid-scale) stress of the temporally filtered Navier-Stokes equations are carefully examined. Causal time-domain filters, parameterized by a temporal filter width 0 less than Delta less than infinity, are considered. For several reasons, the differential forms of such filters are preferred to their corresponding integral forms; among these, storage requirements for differential forms are typically much less than for integral forms and, for some filters, are independent of Delta. The behavior of the residual stress in the limits of both vanishing and in infinite filter widths is examined. It is shown analytically that, in the limit Delta to 0, the residual stress vanishes, in which case the Navier-Stokes equations are recovered from the temporally filtered equations. Alternately, in the limit Delta to infinity, the residual stress is equivalent to the long-time averaged stress, and the Reynolds-averaged Navier-Stokes equations are recovered from the temporally filtered equations. The predicted behavior at the asymptotic limits of filter width is further validated by numerical simulations of the temporally filtered forced, viscous Burger's equation. Finally, finite filter widths are also considered, and a priori analyses of temporal similarity and temporal approximate deconvolution models of the residual stress are conducted.

Pruett, C. D.↗