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At least 55 records · Page 3

Modeling Fatigue Damage Onset and Progression in Composites Using an Element-Based Virtual Crack Closure Technique Combined With the Floating Node Method

A new methodology is proposed to model the onset and propagation of matrix cracks and delaminations in carbon-epoxy composites subject to fatigue loading. An extended interface element, based on the Floating Node Method, is developed to represent delaminations and matrix cracks explicitly in a mesh independent fashion. Crack propagation is determined using an element-based Virtual Crack Closure Technique approach to determine mixed-mode energy release rates, and the Paris-Law relationship to obtain crack growth rate. Crack onset is determined using a stressbased onset criterion coupled with a stress vs. cycle curve and Palmgren-Miner rule to account for fatigue damage accumulation. The approach is implemented in Abaqus/Standard® via the user subroutine functionality. Verification exercises are performed to assess the accuracy and correct implementation of the approach. Finally, it was demonstrated that this approach captured the differences in failure morphology in fatigue for two laminates of identical stiffness, but with layups containing θdeg plies that were either stacked in a single group, or distributed through the laminate thickness.

De Carvalho, Nelson V.↗

Fatigue Crack Growth in Peened Friction Stir Welds

Friction stir welding induces residual stresses that accelerates fatigue crack growth in the weld nugget. Shot peening over the weld had little effect on growth rate. Laser peening over the weld retarded the growth rate: Final crack growth rate was comparable to the base, un-welded material. Crack tunneling evident from residual compressive stresses. 2195-T8 fracture surfaces were highly textured. Texturing makes comparisons difficult as the material system is affecting the data as much as the processing. Material usage becoming more common in space applications requiring additional work to develop useful datasets for damage tolerance analyses.

Forth, Scott C.↗

In Situ Measurement of Stress Corrosion Crack Tip Properties During Environmentally Induced Cracking in Stainless Steel 304L

The influence of the external cathodic area, stress intensity, and electrochemical polarization level on the resultant crack growth rate and crack tip pH and potential was studied for stainless steel 304L in a sodium chloride environment. Before testing, the validity of in situ crack tip property measurements using microprobes and drilled holes was supported through modeling efforts and confirmed with experimental observations. Here, it was found that increasing the R-ratio during corrosion fatigue increased the crack growth rate and decreased the measured crack tip pH of the 304L sample. Decreasing the electrochemical potential (i.e., cathodic polarization) of the bulk sample increased the crack tip pH and stopped measured crack extension under constant K conditions. Conversely, increasing the potential of the bulk sample decreased the crack tip pH and induced cracking under constant K conditions. Decreasing the cathodic area external to the crack increased the measured pH at the crack tip and decreased the crack growth rate under fatigue conditions. For the given configuration, environment, and alloy studied, fatigue crack growth is not sustained by cathodic reactions solely occurring in the crack wake and notch. These results have implications for the ability to predict atmospheric crack growth rates from laboratory, full immersion experiments.

corrosion fatigue↗

An Analytical Tool for Fracture Control

The structural integrity of critical NASA space flight hardware is ensured through a damage tolerance program which is dictated in the fracture control requirements. The goal of a fracture control program is to ensure proper material selection and control, control of working stress levels, use of fracture resistant design concepts, manufacturing process control, and the use of qualified inspection procedures. The damage tolerance philosophy assumes that all components contain initial defects and the damage accumulation process is thus entirely crack propagation. The service capability of fracture critical components is determined by analysis and/or test. A large percentage of NASA fracture critical hardware is certified by analysis only and it is therefore imperative that the analysis code utilized contain the latest state of the art technology. Not all space contractors and vendors are able to develop and maintain an analysis code which meets this requirement. A response to this need has been fulfilled by the development of the NASA/FLAGRO (NASGRO) fracture mechanics code here at the Johnson Space Center. The NASGRO code is based primarily in Linear Elastic Fracture Mechanics (LEFM) and is continually updated to meet to needs of the user community. Development assistance comes from other NASA centers as well as the European Space Agency (ESA). The code currently has a vast materials data file (over 350 different entries) which defines the material strength, fracture toughness, crack growth rate, and crack growth threshold. The code also allows for user defined inputs of data from other sources. The code also provides a large library of stress intensity factor solutions for numerous geometries and loading conditions.

Patin, Raymond M.↗

An Evaluation of the Plasticity-Induced Crack-Closure Concept and Measurement Methods

An assessment of the plasticity-induced crack-closure concept is made, in light of some of the questions that have been raised on the validity of the concept, and the assumptions that have been made concerning crack-dp damage below the crack-opening stress. The impact of using other crack-tip parameters, such as the cyclic crack-tip displacement, to model crack-growth rate behavior was studied. Crack-growth simulations, using a crack-closure model, showed a close relation between traditional Delta K eff, and the cyclic crack-tip displacement (Delta eff) for an aluminum alloy and a steel. Evaluations of the cyclic hysteresis energy demonstrated that the cyclic plastic damage below the crack-opening stress was negligible in the Paris crack-growth regime. Some of the standard and newly proposed remote measurement methods to determine the 'effective' crack-tip driving parameter were evaluated on middle-crack tension specimens. A potential source of the Kmax effect on crack-growth rates was studied on an aluminum alloy. Results showed that the ratio of Kmax to Kc had a strong effect on crack-growth rates at high stress ratios and at low stress ratios for very high stress levels. The crack-closure concept and the traditional crack-growth rate equations were able to correlate and predict crack-growth rates under these extreme conditions.

Newman, James C., Jr.↗

The effect of material heterogeneity and random loading on the mechanics of fatigue crack growth

This paper reviews experimental work on the influence of variable amplitude or random loads on the mechanics and micromechanisms of fatigue crack growth. Implications are discussed in terms of the crack driving force, local plasticity, crack closure, crack blunting, and microstructure. Due to heterogeneity in the material's microstructure, the crack growth rate varies with crack tip position. Using the weakest link theory, an expression for crack growth rate is obtained as the expectation of a random variable. This expression is used to predict the crack growth rates for aluminum alloys, a titanium alloy, and a nickel steel in the mid-range region. It is observed, using the present theory, that the crack growth rate obeys the power law for small stress intensity factor range, and that the power is a function of a material constant.

Srivatsan, T. S.↗

Cyclic plasticity models and application in fatigue analysis

An analytical procedure for prediction of the cyclic plasticity effects on both the structural fatigue life to crack initiation and the rate of crack growth is presented. The crack initiation criterion is based on the Coffin-Manson formulae extended for multiaxial stress state and for inclusion of the mean stress effect. This criterion is also applied for the accumulated damage ahead of the existing crack tip which is assumed to be related to the crack growth rate. Three cyclic plasticity models, based on the concept of combination of several yield surfaces, are employed for computing the crack growth rate of a crack plane stress panel under several cyclic loading conditions.

Kalev, I.↗

An inverse method for the calculation of through-thickness fatigue crack closure behavior

An inverse technique was used to calculate through-thickness fatigue crack closure behavior. The through-thickness variation in crack opening stress-intensity factor was calculated by considering the variation in the three-dimensional stress-intensity factor, the variation in crack growth rate along the crack front, and a relationship between the crack growth rate and effective stress-intensity factor range (da/dN-Delta-K(eff)). The three-dimensional stress-intensity factor variation was obtained from an elastic finite element analysis of specific crack-front profiles observed experimentally. The variation in crack growth rate along the crack front was obtained experimentally from comparison of observed crack front changes. The da/dN-Delta-K(eff) relationship was estimated from high stress ratio, constant load amplitude, and fatigue crack growth tests. The through-thickness crack opening stress-intensity factor results agreed with crack opening measurements obtained from fatigue striations, near-tip strain gages, and remote strain and displacement gages.

Dawicke, D. S.↗

The effect of water vapor on fatigue crack Growth in 7475-t651 aluminum alloy plate

The effects of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate at frequencies of 1 Hz and 10 Hz were investigated. Twenty-five mm thick compact specimens were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Fatigue crack growth rates were calculated from effective crack lengths determined using a compliance method. Tests were conducted in hard vacuum and at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. Fatigue crack growth rates were frequency insensitive under all environment conditions tested. For constant stress intensity factor ranges crack growth rate transitions occurred at low and high water vapor pressures. Crack growth rates at intermediate pressures were relatively constant and showed reasonable agreement with published data for two Al-Cu-Mg alloys. The existence of two crack growth rate transitions suggests either a change in rate controlling kinetics or a change in corrosion fatigue mechanism as a function of water vapor pressure. Reduced residual deformation and transverse cracking specimens tested in water vapor versus vacuum may be evidence of embrittlement within the plastic zone due to environmental interaction.

Dicus, D. L.↗

Effect of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate

The effects of water vapor on fatigue crack growth in 7475-T651 aluminum alloy plate at frequencies of 1 Hz and 10 Hz were investigated. Twenty-five mm thick compact specimens were subjected to constant amplitude fatigue testing at a load ratio of 0.2. Fatigue crack growth rates were calculated from effective crack lengths determined using a compliance method. Tests were conducted in hard vacuum and at water vapor partial pressures ranging from 94 Pa to 3.8 kPa. Fatigue crack growth rates were frequency insensitive under all environment conditions tested. For constant stress intensity factor ranges crack growth rate transitions occurred at low and high water vapor pressures. Crack growth rates at intermediate pressures were relatively constant and showed reasonable agreement with published data for two Al-Cu-Mg alloys. The existence of two crack growth rate transitions suggests either a change in rate controlling kinetics or a change in corrosion fatigue mechanism as a function of water vapor pressure. Reduced residual deformation and transverse cracking specimens tested in water vapor versus vacuum may be evidence of embrittlement within the plastic zone due to environmental interaction.

Dicus, D. L.↗

Distribution of Inclusion-Initiated Fatigue Cracking in Powder Metallurgy Udimet 720 Characterized

In the absence of extrinsic surface damage, the fatigue life of metals is often dictated by the distribution of intrinsic defects. In powder metallurgy (PM) alloys, relatively large defects occur rarely enough that a typical characterization with a limited number of small volume fatigue test specimens will not adequately sample inclusion-initiated damage. Counterintuitively, inclusion-initiated failure has a greater impact on the distribution in PM alloy fatigue lives because they tend to have fewer defects than their cast and wrought counterparts. Although the relative paucity of defects in PM alloys leads to higher mean fatigue lives, the distribution in observed lives tends to be broader. In order to study this important failure initiation mechanism without expending an inordinate number of specimens, a study was undertaken at the NASA Glenn Research Center where known populations of artificial inclusions (seeds) were introduced to production powder. Fatigue specimens were machined from forgings produced from the seeded powder. Considerable effort has been expended in characterizing the crack growth rate from inclusion-initiated cracks in seeded PM alloys. A rotating and translating positioning system, with associated software, was devised to map the surface inclusions in low-cycle fatigue (LCF) test bars and to monitor the crack growth from these inclusions. The preceding graph illustrates the measured extension in fatigue cracks from inclusions on a seeded LCF test bar subjected to cyclic loading at a strain range of 0.8 percent and a strain ratio (max/min) of zero. Notice that the observed inclusions fall into three categories: some do not propagate at all (arrest), some propagate with a decreasing crack growth rate, and a few propagate at increasing rates that can be modeled by fracture mechanics. The following graph shows the measured inclusion-initiated crack growth rates from 10 interrupted LCF tests plotted against stress intensities calculated for semi-elliptical cracks with the observed surface lengths. The expected scatter in the crack growth rates for stress intensity ranges near threshold is observed. These data will be used to help determine the distribution in growth rates of cracks emanating from inclusions as well as the proportion of cracks that arrest under various loading conditions.

Bonacuse, Peter J.↗

A probabilistic fatigue analysis of multiple site damage

The variability in initial crack size and fatigue crack growth is incorporated in a probabilistic model that is used to predict the fatigue lives for unstiffened aluminum alloy panels containing multiple site damage (MSD). The uncertainty of the damage in the MSD panel is represented by a distribution of fatigue crack lengths that are analytically derived from equivalent initial flaw sizes. The variability in fatigue crack growth rate is characterized by stochastic descriptions of crack growth parameters for a modified Paris crack growth law. A Monte-Carlo simulation explicitly describes the MSD panel by randomly selecting values from the stochastic variables and then grows the MSD cracks with a deterministic fatigue model until the panel fails. Different simulations investigate the influences of the fatigue variability on the distributions of remaining fatigue lives. Six cases that consider fixed and variable conditions of initial crack size and fatigue crack growth rate are examined. The crack size distribution exhibited a dominant effect on the remaining fatigue life distribution, and the variable crack growth rate exhibited a lesser effect on the distribution. In addition, the probabilistic model predicted that only a small percentage of the life remains after a lead crack develops in the MSD panel.

Rohrbaugh, S. M.↗

The growth of short cracks in 4340 steel and aluminum-lithium 2090

The objectives were to investigate crack initiation characteristics and short crack growth behavior for Al-Li 2090 and for 4340 steel and to evaluate the ability of a closure-based crack-growth model to predict fatigue crack growth rates and total fatigue lives for the steel. Single-edge-notched tension specimens of each alloy were used to obtain the short crack growth rate information via an acetate replica technique. In addition to constant amplitude loading, tests on the steel were conducted using the Felix/28 variable amplitude spectrum (a shortened form of a standard loading sequence for fixed or semi-rigid helicopter rotors). The short crack growth rates were compared to those for long cracks grown under similar loading conditions. Metallurgical features associated with crack initiation are discussed. For Al-Li 2090 under R = -1 loading, the short cracks grew well below the long crack threshold and grew at acute angles to the loading axis. For 4340 steel under constant amplitude loading at R = 0.5 and 0 and for the Felix/28 spectrum loading, short-crack growth rates agreed well with long-crack growth rates, even near the long-crack threshold. A slight short-crack effect, growth below the long-crack threshold, was observed at R = -1. Fatigue lives were found to depend on the size and type of initiation site, especially for the Felix/28 loading sequence. A semi-empirical crack-growth model incorporating crack-closure effects was used to predict crack growth rates and total fatigue lives of notched 4340 steel specimens. An initial defect size and shape typical of those identified in this steel was assumed for the life predictions. For all loading conditions, reasonable agreement was found between measured and predicted values for both crack growth rates and fatigue lives.

Swain, M. H.↗

Development of the NASA/FLAGRO computer program

A preliminary version of a new computer program has been developed for calculating crack propagation in cyclically loaded structures. The new program, titled NASA/FLAGRO, has numerous enhanced features over previous programs used for safe life analysis on space systems. The essential features of the new program consist of modular design, promptive input using a cathode ray tube terminal, improved crack growth rate analytical methods, many new crack case solutions, and incorporation of user-defined files for material properties and fatigue spectrums. Also, five options made available in the program are to compute: (1) safe life of a part with a preexisting crack; (2) critical crack size for a specified stress level; (3) stress-intensity factor numerical values for making comparisons or checks of solutions; (4) least-squares fit of growth rate equations to crack growth rate data; and (5) the conversion of a versus N data to Delta K versus da/dN.

Forman, Royce G.↗

The growth of small corrosion fatigue cracks in alloy 2024

The corrosion fatigue crack growth characteristics of small surface and corner cracks in aluminum alloy 2024 is established. The damaging effect of salt water on the early stages of small crack growth is characterized by crack initiation at constituent particle pits, intergranular microcracking for a less than 100 micrometers, and transgranular small crack growth for a micrometer. In aqueous 1 percent NaCl and at a constant anodic potential of -700 mV(sub SCE), small cracks exhibit a factor of three increase in fatigue crack growth rates compared to laboratory air. Small cracks exhibit accelerated corrosion fatigue crack growth rates at low levels of delta-K (less than 1 MPa square root of m) below long crack delta-K (sub th). When exposed to Paris regime levels of crack tip stress intensity, small corrosion fatigue cracks exhibit growth rates similar to that observed for long cracks. Results suggest that crack closure effects influence the corrosion fatigue crack growth rates of small cracks (a less than or equal to 100 micrometers). This is evidenced by similar small and long crack growth behavior at various levels of R. Contrary to the corrosion fatigue characteristics of small cracks in high strength steels, no pronounced chemical crack length effect is observed for Al by 2024 exposed to salt water.

Piascik, Robert S.↗

Statistical mechanical model for crack growth

Analytic relations that describe crack growth are vital for modeling experiments and building a theoretical understanding of fracture. Upon constructing an idealized model system for the crack and applying the principles of statistical thermodynamics, it is possible to formulate the rate of thermally activated crack growth as a function of load, but the result is analytically intractable. In this report an asymptotically correct theory is used to obtain analytic approximations of the crack growth rate from the fundamental theoretical formulation. These crack growth rate relations are compared to those that exist in the literature and are validated with respect to Monte Carlo calculations and experiments. The success of this approach is encouraging for future modeling endeavors that might consider more complicated fracture mechanisms, such as inhomogeneity or a reactive environment.

36 MATERIALS SCIENCE↗

NASA Ground-based Layered Pressure Vessels Materials Report

A significant portion of Layered Pressure Vessels (LPVs) manufactured for NASA in the 1950s and ’60s are of non-code construction. These vessels were constructed to the standards of individual manufacturers rather than an industry or consensus standard and often contain legacy or proprietary materials, which have poor or no characterization. Obtaining correct material properties is the first step in assuring vessel safety and predicting life and critical failure modes before they happen. This report details the efforts of the LPV Project related to material properties and characterization. The goal in testing materials from deconstructed vessels was to provide material characterization utilizing modern test methods that would give a strong probabilistic base as an option for future analysis. ASTM E1820, Standard Test Method for Measurement of Fracture Toughness was used for fracture toughness; ASTM E1921, Standard Test Method for Determination of Reference Temperature, T0, for Ferritic Steels in the Transition Range for transition temperature; and ASTM E647, Standard Test Method for Measurement of Fatigue Crack Growth Rates for fatigue crack growth. Particular focus was placed on determination of transition temperature through evaluation of the T0 reference temperature in accordance with ASTM E1921. Transition temperature testing allows for a probabilistic analysis of vessel materials that may be operating at temperatures below the transition from ductile tearing to brittle cleavage failure. This test method was not available at the time of construction and has proved invaluable to the characterization of older ferritic steels. The values reported are specific to the largest body of materials found in the current NASA fleet, but do not claim to be all inclusive. As demonstrated in this report, some materials contain extreme lot-to-lot variability. In some cases, this can be comfortably bounded by worst case probabilistic methods, however it is always recommended that vessel specific data be collected in as much depth as possible to ensure correct assumptions and avoid unduly restricting vessel usage.

Layered Pressure Vessel↗

Crack growth in ASME SA-105 grade 2 steel in hydrogen at ambient temperature

Cyclic-load crack growth measurements were performed on ASME SA-105 Grade 2 steel specimens exposed to 10,000- and 15,000-psi hydrogen and to 5000-psi helium, all at ambient temperatures. The cyclic-load crack growth rate was found to be faster in high-pressure hydrogen than in helium. Cyclic-load crack growth rates in this steel were not reduced by preloading in air to a stress intensity of 1.5 times the cyclic K sub max in hydrogen. There are indications that holding under load in hydrogen, and loading and unloading in helium retards hydrogen-accelerated cyclic-load crack growth. Cyclic frequency and R (ratio of K sub min/k sub max) were important variables determining crack growth rate. The crack growth rate increased as a logarithm of the cycle duration and decreased with increasing R.

Walter, R. J.↗