The Design of Brittle-material Blade Roots Based on Theory and Rupture Tests of Plastic Models
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Meyer, Andre J , Jr↗
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The Design of Brittle-material Blade Roots Based on Theory and Rupture Tests of Plastic Models
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Meyer, Andre J , Jr↗
Reliability Analysis of Uniaxially Ground Brittle Materials
The fast fracture strength distribution of uniaxially ground, alpha silicon carbide was investigated as a function of grinding angle relative to the principal stress direction in flexure. Both as-ground and ground/annealed surfaces were investigated. The resulting flexural strength distributions were used to verify reliability models and predict the strength distribution of larger plate specimens tested in biaxial flexure. Complete fractography was done on the specimens. Failures occurred from agglomerates, machining cracks, or hybrid flaws that consisted of a machining crack located at a processing agglomerate. Annealing eliminated failures due to machining damage. Reliability analyses were performed using two and three parameter Weibull and Batdorf methodologies. The Weibull size effect was demonstrated for machining flaws. Mixed mode reliability models reasonably predicted the strength distributions of uniaxial flexure and biaxial plate specimens.
Salem, Jonathan A.↗
Cyclic Fatigue of Brittle Materials with an Indentation-Induced Flaw System
The ratio of static to cyclic fatigue life, or 'h ratio', was obtained numerically for an indentation flaw system subjected to sinusoidal loading conditions. Emphasis was placed on developing a simple, quick lifetime prediction tool. The solution for the h ratio was compared with experimental static and cyclic fatigue data obtained from as-indented 96 wt.% alumina specimens tested in room-temperature distilled water.
Choi, Sung R.↗
Slow Crack Growth of Brittle Materials With Exponential Crack-Velocity Formulation: Analysis - Part 1
Extensive slow-crack-growth (SCG) analysis was made using a primary exponential crack-velocity formulation under three widely used load configurations: constant stress rate, constant stress, and cyclic stress. Although the use of the exponential formulation in determining SCG parameters of a material requires somewhat inconvenient numerical procedures, the resulting solutions presented gave almost the same degree of simplicity in both data analysis and experiments as did the power-law formulation. However, the fact that the inert strength of a material should be known in advance to determine the corresponding SCG parameters was a major drawback of the exponential formulation as compared with the power-law formulation.
Choi, Sung R.↗
Slow Crack Growth of Brittle Materials With Exponential Crack-Velocity Formulation: Constant Stress Rate Experiments - Part 2
The previously determined life prediction analysis based on an exponential crack-velocity formulation was examined using a variety of experimental data on glass and advanced structural ceramics in constant stress rate and preload testing at ambient and elevated temperatures. The data fit to the relation of strength versus the log of the stress rate was very reasonable for most of the materials. Also, the preloading technique was determined equally applicable to the case of slow-crack-growth (SCG) parameter n greater than 30 for both the power-law and exponential formulations. The major limitation in the exponential crack-velocity formulation, however, was that the inert strength of a material must be known a priori to evaluate the important SCG parameter n, a significant drawback as compared with the conventional power-law crack-velocity formulation.
Choi, Sung R.↗
Slow Crack Growth of Brittle Materials With Exponential Crack-Velocity Formulation: Constant Stress and Cyclic Stress Experiments - Part 3
The previously determined life prediction analysis based on an exponential crack-velocity formulation was examined using a variety of experimental data on advanced structural ceramics tested under constant stress and cyclic stress loading at ambient and elevated temperatures. The data fit to the relation between the time to failure and applied stress (or maximum applied stress in cyclic loading) was very reasonable for most of the materials studied. It was also found that life prediction for cyclic stress loading from data of constant stress loading in the exponential formulation was in good agreement with the experimental data, resulting in a similar degree of accuracy as compared with the power-law formulation. The major limitation in the exponential crack-velocity formulation, however, was that the inert strength of a material must be known a priori to evaluate the important slow-crack-growth (SCG) parameter n, a significant drawback as compared with the conventional power-law crack-velocity formulation.
Choi, Sung R.↗
Edge notched disc test for evaluation of mode-I fracture toughness of brittle material
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Hadi Haeri↗
Tensile Fracture of Ductile Materials
For brittle materials, circular voids play an important role relative to fracture, intensifing both tensile and compressive stresses. A maximum intensified tensile stress failure criterion applies quite well to brittle materials. An attempt was made to explore the possibility of extending the approach to the tensile fracture of ductile materials. The three dimensional voids that exist in reality are modelled by circular holes in sheet metal. Mathematical relationships are sought between the shape and size of the hole, after the material is plastically deformed, and the amount of deformation induced. Then, the effect of hole shape, size and orientation on the mechanical properties is considered experimentally. The presence of the voids does not affect the ultimate tensile strength of the ductile materials because plastic flow wipes out the stress intensification caused by them. However, the shape and orientation of the defect is found to play an important role in affecting the strain at fracture.
Pai, D. M.↗
An educational program on structural design with brittle /ceramic/ materials
The organization of a proposed ceramic structural materials program is described, and a suggested course sequence for college-level and graduate-level courses is presented. The course work on ceramics and brittle fracture are intended to lead to a brittle material design project and a brittle material design problem. Criteria for the selection of appropriate projects/problems are considered.
Mueller, J. I.↗
Integrity of Ceramic Parts Predicted When Loads and Temperatures Fluctuate Over Time
Brittle materials are being used, and being considered for use, for a wide variety of high performance applications that operate in harsh environments, including static and rotating turbine parts for unmanned aerial vehicles, auxiliary power units, and distributed power generation. Other applications include thermal protection systems, dental prosthetics, fuel cells, oxygen transport membranes, radomes, and microelectromechanical systems (MEMS). In order for these high-technology ceramics to be used successfully for structural applications that push the envelope of materials capabilities, design engineers must consider that brittle materials are designed and analyzed differently than metallic materials. Unlike ductile metals, brittle materials display a stochastic strength response because of the combination of low fracture toughness and the random nature of the size, orientation, and distribution of inherent microscopic flaws. This plus the fact that the strength of a component under load may degrade over time because of slow crack growth means that a probabilistic-based life-prediction methodology must be used when the tradeoffs of failure probability, performance, and useful life are being optimized. The CARES/Life code (which was developed at the NASA Glenn Research Center) predicts the probability of ceramic components failing from spontaneous catastrophic rupture when these components are subjected to multiaxial loading and slow crack growth conditions. Enhancements to CARES/Life now allow for the component survival probability to be calculated when loading and temperature vary over time.
Nemeth, Noel N.↗
Effect of size on cracking of materials
Brittle behavior of large mild steel elements, glass plasticity, and fatigue specimen size sensitivity are manifestations of strain-energy size effect. Specimens physical size effect on material cracking initiation occurs according to flaw distribution statistics. Fracture size effect depends on stability or instability of crack propagation.
Glucklick, J.↗
Unit-Sphere Multiaxial Stochastic-Strength Model Applied to Anisotropic and Composite Materials
Models that predict the failure probability of brittle materials under multiaxial loading have been developed by authors such as Batdorf, Evans, and Matsuo. These "unit-sphere" models assume that the strength-controlling flaws are randomly oriented, noninteracting planar microcracks of specified geometry but of variable size. This methodology has been extended to predict the multiaxial strength response of transversely isotropic brittle materials, including polymer matrix composites (PMCs), by considering (1) flaw-orientation anisotropy, whereby a preexisting microcrack has a higher likelihood of being oriented in one direction over another direction, and (2) critical strength, or K (sub Ic) orientation anisotropy, whereby the level of critical strength or fracture toughness for mode I crack propagation, K (sub Ic), changes with regard to the orientation of the microstructure. In this report, results from finite element analysis of a fiber-reinforced-matrix unit cell were used with the unit-sphere model to predict the biaxial strength response of a unidirectional PMC previously reported from the World-Wide Failure Exercise. Results for nuclear-grade graphite materials under biaxial loading are also shown for comparison. This effort was successful in predicting the multiaxial strength response for the chosen problems. Findings regarding stress-state interactions and failure modes also are provided.
Nemeth, Noel, N.↗
Eccentric loading of microtensile specimens
Ceramic materials have a lower density than most metals and are capable of performing at extremely high temperatures. The utility of these materials is obvious; however, the fracture strength of brittle materials is not easily predicted and often varies greatly. Characteristically, brittle materials lack ductility and do not yield as other materials. Ceramics materials are naturally populated with microscopic cracks due to fabrication techniques. Upon application of a load, stress concentration occurs at the root of these cracks and fracture will eventually occur at some not easily predicted strength. In order to use ceramics in any application some design methodology must exist from which a component can be placed into service. This design methodology is CARES/LIFE (Ceramics Analysis and Reliability Evaluation of Structures) which has been developed and refined at NASA over the last several decades. The CARES/LIFE computer program predicts the probability of failure of a ceramic component over its service life. CARES combines finite element results from a commercial FE (finite element) package such as ANSYS and experimental results to compute the abovementioned probability of failure. Over the course of several tests CARES has had great success in predicting the life of various ceramic components and has been used throughout industry. The latest challenge is to verify that CARES is valid for MEMS (Micro-Electro Mechanical Systems). To investigate a series of microtensile specimens were fractured in the laboratory. From this data, material parameters were determined and used to predict a distribution of strength for other specimens that exhibit a known stress concentration. If the prediction matches the experimental results then these parameters can be applied to a desired component outside of the laboratory. During testing nearly half of the tensile Specimens fractured at a location that was not expected and hence not captured in the FE model. It has been my duty to investigate the nature of this phenomenon in hopes of finding a better correlation between theory and empirical results. To investigate I built complete FE models of all of the tensile specimens using ANSYS. It is suspected that some misalignment naturally occurs during testing and thus additional bending stresses are present in the specimens. I modeled this eccentric loading and ran several FE trials using ANSYS/PDS (a probabilistic design system in ANSYS). My objective this summer has been familiarize myself with the CARES/LIFE program in hopes of using it in conjunction with ANSYS to help verify that CARES is applicable to MEMS-scale (greater that 1 micron, less than 1 millimeter) components.
Trapp, Mark A.↗
Award-Winning CARES/Life Ceramics Durability Evaluation Software Is Making Advanced Technology Accessible
Products made from advanced ceramics show great promise for revolutionizing aerospace and terrestrial propulsion and power generation. However, ceramic components are difficult to design because brittle materials in general have widely varying strength values. The CARES/Life software developed at the NASA Lewis Research Center eases this by providing a tool that uses probabilistic reliability analysis techniques to optimize the design and manufacture of brittle material components. CARES/Life is an integrated package that predicts the probability of a monolithic ceramic component's failure as a function of its time in service. It couples commercial finite element programs--which resolve a component's temperature and stress distribution - with reliability evaluation and fracture mechanics routines for modeling strength - limiting defects. These routines are based on calculations of the probabilistic nature of the brittle material's strength.
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Measuring the Weibull modulus of microscope slides
The objectives are that students will understand why a three-point bending test is used for ceramic specimens, learn how Weibull statistics are used to measure the strength of brittle materials, and appreciate the amount of variation in the strength of brittle materials with low Weibull modulus. They will understand how the modulus of rupture is used to represent the strength of specimens in a three-point bend test. In addition, students will learn that a logarithmic transformation can be used to convert an exponent into the slope of a straight line. The experimental procedures are explained.
Sorensen, Carl D.↗
Scanning electron acoustic microscopy of residual stresses in ceramics: Theory and experiment
Several reviews have highlighted a number of applications of scanning electron acoustic microscopy (SEAM) to metals and semiconductors which show that SEAM can provide new information on surface and near-surface features of such materials, but there have been few studies attempting to determine the capabilities of SEAM for characterizing ceramic materials. We have recently observed image contrast in SEAM from residual stress fields induced in brittle materials by Vickers indentations that is strongly dependent on the electron beam chopping frequency. We have also recently developed a three-dimensional mathematical model of signal generation and contrast in SEAM, appropriate to the brittle materials studied, that we use as a starting point in this paper for modeling the effect of residual stress fields on the generated electron acoustic signal. The influence of the electron beam chopping frequency is also considered under restrictive assumptions.
Cantrell, John H.↗
Reliability Modeling of Brittle Anisotropic Materials
A significant effort is being made to develop testing and design methodologies that will account for the lack of ductility and the strength anisotropy exhibited by brittle single crystals such as NiAl. The present approach is to modify existing test methods and brittle design methodologies, such as those applied to ceramics and glasses, and to experimentally verify the results. This paper focuses on the basic materials properties and strength behavior of a NiAl single crystal alloy and the development of a reliability model for the design of components subjected to multiaxial stresses.
Conceivably↗