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NASA NTRS2012

Damage Tolerance Assessment of Friction Pull Plug Welds in an Aluminum Alloy

Friction stir welding is a solid state welding process used in the fabrication of cryogenic propellant tanks. Self-reacting friction stir welding is one variation of the friction stir weld process being developed for manufacturing tanks. Friction pull plug welding is used to seal the exit hole that remains in a circumferential self-reacting friction stir weld. A friction plug weld placed in a self-reacting friction stir weld results in a non-homogenous weld joint where the initial weld, plug weld, their respective heat affected zones and the base metal all interact. The welded joint is a composite plastically deformed material system with a complex residual stress field. In order to address damage tolerance concerns associated with friction plug welds in safety critical structures, such as propellant tanks, nondestructive inspection and proof testing may be required to screen hardware for mission critical defects. The efficacy of the nondestructive evaluation or the proof test is based on an assessment of the critical flaw size. Test data relating residual strength capability to flaw size in an aluminum alloy friction plug weld will be presented.

McGill, Preston↗

NASA NTRS1996

Controlling Flexible Robot Arms Using High Speed Dynamics Process

A robot manipulator controller for a flexible manipulator arm having plural bodies connected at respective movable hinges and flexible in plural deformation modes corresponding to respective modal spatial influence vectors relating deformations of plural spaced nodes of respective bodies to the plural deformation modes, operates by computing articulated body quantities for each of the bodies from respective modal spatial influence vectors, obtaining specified body forces for each of the bodies, and computing modal deformation accelerations of the nodes and hinge accelerations of the hinges from the specified body forces, from the articulated body quantities and from the modal spatial influence vectors. In one embodiment of the invention, the controller further operates by comparing the accelerations thus computed to desired manipulator motion to determine a motion discrepancy, and correcting the specified body forces so as to reduce the motion discrepancy. The manipulator bodies and hinges are characterized by respective vectors of deformation and hinge configuration variables, and computing modal deformation accelerations and hinge accelerations is carried out for each one of the bodies beginning with the outermost body by computing a residual body force from a residual body force of a previous body and from the vector of deformation and hinge configuration variables, computing a resultant hinge acceleration from the body force, the residual body force and the articulated hinge inertia, and revising the residual body force modal body acceleration.

Jain, Abhinandan↗

NASA NTRS1980

Multi-Parameter Yield Zone Model for Predicting Spectrum Crack Growth

A systematic technique is presented for modeling crack growth load interaction effects due to spectrum loading. The Multi-Parameter Yield Zone (MPYZ) model accounts for crack growth retardation, acceleration, and underload effects. The load interactions are attributed to the residual stress intensity due to the plastic deformation at the crack tip. Fatigue crack growth was predicted and compared with test data for a variety of spectrum loadings.

Johnson, W. S.↗

NASA NTRS2011

Full-Scale Test and Analysis of a PRSEUS Fuselage Panel to Assess Damage-Containment Features

Stitched composite technology has the potential to substantially decrease structural weight through enhanced damage containment capabilities. The most recent generation of stitched composite technology, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, has been shown to successfully arrest damage at the sub-component level through tension testing of a three stringer panel with damage in the form of a two-bay notch. In a joint effort undertaken by the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and the Boeing Company, further studies are being conducted to characterize the damage containment features of the PRSEUS concept. A full-scale residual strength test will be performed on a fuselage panel to determine if the load capacity will meet strength, deformation, and damage tolerance requirements. A curved panel was designed, fabricated, and prepared for residual strength testing. A pre-test Finite Element Model (FEM) was developed using design allowables from previous test programs to predict test panel deformation characteristics and margins of safety. Three phases of testing with increasing damage severity include: (1) as manufactured; (2) barely visible impact damage (BVID) and visible impact damage (VID); and (3) discrete source damage (DSD) where the panel will be loaded to catastrophic failure. This paper presents the background information, test plan, and experimental procedure. This paper is the first of several future articles reporting the test preparations, results, and analysis conducted in the test program.

Bergan, Andrew↗

NASA NTRS1998

Low-Temperature Friction-Stir Welding of 2024 Aluminum

Solid state friction-stir welding (FSW) has been demonstrated to involve dynamic recrystallization producing ultra-fine, equiaxed grain structures to facilitate superplastic deformation as the welding or joining mechanism. However, the average residual, equiaxed, grain size in the weld zone has ranged from roughly 0.5 micron to slightly more than 10 micron, and the larger weld zone grain sizes have been characterized as residual or static grain growth as a consequence of the temperatures in the weld zone (where center-line temperatures in the FSW of 6061 Al have been shown to be as high as 480C or -0.8 T(sub M) where T(sub M) is the absolute melting temperature)). In addition, the average residual weld zone grain size has been observed to increase near the top of the weld, and to decrease with distance on either side of the weld-zone centerline, an d this corresponds roughly to temperature variations within the weld zone. The residual grain size also generally decreases with decreasing FSW tool rotation speed. These observations are consistent with the general rules for recrystallization where the recrystallized grain size decreases with increasing strain (or deformation) at constant strain rate, or with increasing strain-rate, or with increasing strain rate at constant strain; especially at lower ambient temperatures, (or annealing temperatures). Since the recrystallization temperature also decreases with increasing strain rate, the FSW process is somewhat complicated because the ambient temperature, the frictional heating fraction, and the adiabatic heating fraction )proportional to the product of strain and strain-rate) will all influence both the recrystallization and growth within the FSW zone. Significantly reducing the ambient temperature of the base metal or work pieces to be welded would be expected to reduce the residual weld-zone grain size. The practical consequences of this temperature reduction would be the achievement of low temperature welding. This study compares the residual grain sizes and microstructures in 2024 Al friction-stir welded at room temperature (about 30C and low temperature (-30C).

Benavides, S.↗

NASA NTRS1992

Fracture and damage; Winter Annual Meeting of the American Society of Mechanical Engineers, Anaheim, CA, Nov. 8-13, 1992

The latest developments in the area of fracture and damage at high temperatures are discussed, in particular: modeling; analysis and experimental techniques for interface damage in composites including the effects of residual stresses and temperatures; and crack growth, inelastic deformation and fracture parameters for isotropic materials. Also included are damage modeling and experiments at elevated temperatures.

Nagar, Arvind↗

NASA NTRS2002

Residual wave front phase estimation in the reimaged lyot plane for the eclipse coronographic telescope

Coronagraphs for extra-solar planet detection remove diffracted stellar light through the combination of a coronagraphic mask and a Lyot stop. When the entrance pupil contains a nearly perfect wave fiont, most of the stellar light is absorbed at the mask. Light scattered around the spot due to mid- and high-spatial frequency phase errors in the pupil appears at the Lyot plane as speckles whose amplitudes are proportional to the local wave front phase residuals. The speckles scale with optical wavelength but are not radially smeared. The Eclipse deformable mirror (DM) can be used to modify the Lyot amplitude distribution, providing a simple means of estimating the residual phase content and controlling the wave front. To reduce the detrimental noise carried by uncontrollable high-spatial frequency wave front components, theLyot plane signal is filtered at the science plane to pass only the controllable spatial frequencies that contribute to the dark hole. The Lyot stop is then reimaged onto a detector. We demonstrate through simulations that this approach signiscantly improves the signal-to-noise ratio of the planet measurement.

coronagraph wave front sensing wave front control↗

NASA NTRS1989

Multibody dynamics: Modeling component flexibility with fixed, free, loaded, constraint, and residual modes

The assumed-modes method in multibody dynamics allows the elastic deformation of each component in the system to be approximated by a sum of products of spatial and temporal functions commonly known as modes and modal coordinates respectively. The choice of component modes used to model articulating and non-articulating flexible multibody systems is examined. Attention is directed toward three classical Component Mode Synthesis (CMS) methods whereby component normal modes are generated by treating the component interface (I/F) as either fixed, free, or loaded with mass and stiffness contributions from the remaining components. The fixed and free I/F normal modes are augmented by static shape functions termed constraint and residual modes respectively. A mode selection procedure is outlined whereby component modes are selected from the Craig-Bampton (fixed I/F plus constraint), MacNeal-Rubin (free I/F plus residual), or Benfield-Hruda (loaded I/F) mode sets in accordance with a modal ordering scheme derived from balance realization theory. The success of the approach is judged by comparing the actuator-to-sensor frequency response of the reduced order system with that of the full order system over the frequency range of interest. A finite element model of the Galileo spacecraft serves as an example in demonstrating the effectiveness of the proposed mode selection method.

Spanos, John T.↗

NASA NTRS1984

The evaluation of a deformable diffraction grating for a stigmatic EUV spectroheliometer

A second toroidal replica grating was found to have an aspect ratio within 10% of the desire value. The aspect ratio of replica toroidal gratings is coming out somewhat low. Whether this is caused by some relaxation in the epoxy or some residual error in the setup when the replication is made from the deformable submaster grating will be determined. The first imaging tests at EUV wavelengths near 500 A were carried out. The initial results are most encouraging with blur sizes of the order of, or less than, 40 microns. Further focussing and additional photographic tests will be carried out, and preparations made for the first photoelectric measurements of the image quality using the (256 x 1024)-pixel MAMA detection system. The visible-light (256 x 1024)-pixel MAMA detector tube has completed initial evaluation.

Timothy, J. G.↗

NASA NTRS1993

Inelastic deformation mechanisms in SCS-6/Ti 15-3 MMC lamina under compression

An investigation was undertaken to study the inelastic deformation mechanisms in (0)(sub 8) and (90)(sub 8) Ti 15-3/SCS-6 lamina subjected to pure compression. Monotonic tests were conducted at room temperature (RT), 538 C and 650 C. Results indicate that mechanical response and deformation characteristics were different in monotonic tension and compression loading whereas some of those differences could be attributed to residual stress effects. There were other differences because of changes in damage and failure modes. The inelastic deformation in the (0)(sub 8) lamina under compression was controlled primarily by matrix plasticity, although some evidence of fiber-matrix debonding was observed. Failure of the specimen in compression was due to fiber buckling in a macroscopic shear zone (the failure plane). The inelastic deformation mechanisms under compression in (90)(sub 8) lamina were controlled by radial fiber fracture, matrix plasticity, and fiber-matrix debonding. The radial fiber fracture was a new damage mode observed for MMC's. Constitutive response was predicted for both the (0)(sub 8) and (90)(sub 8) laminae, using AGLPLY, METCAN, and Battelle's Unit Cell FEA model. Results from the analyses were encouraging.

Newaz, Golam M.↗

NASA NTRS1991

Damaged stiffened shell research at NASA. Langley Research Center

The structural behavior of stiffened fuselage shells with local cracks is influenced by the local deformations and stress gradients near the cracks, and this behavior must be understood to predict fuselage structural integrity and residual strength. As a crack grows, the stiffness and internal load distributions in a stiffened shell change, affecting the local deformations and stress gradients near the crack. Transport fuselage shells are designed to support internal pressure and mechanical loads which cause a geometrically nonlinear response. Research is being conducted at NASA LaRC to develop and demonstrate a verified nonlinear stiffened shell analysis methodology for accurately predicting the global and local behavior of nonlinear stiffened fuselage shells with local cracks and with combined internal pressure and mechanical loads. The nonlinear structural analysis methodology being developed and planned at NASA LaRC for damaged stiffened fuselage shells and the experiments being planned to verify this analysis methodology are summarized in the present paper.

Aging Aircraft↗

NASA NTRS1973

Material and structural studies of metal and polymer matrix composites

Fiber-reinforced composites and design analysis methods for these materials are being developed because of the vast potential of composites for decreasing weight and/or increasing use temperature capability in aerospace systems. These composites have potential for use in airbreathing engine components as well as aeronautical and space vehicle structures. Refractory wire-superalloy composites for use up to 2200 F or more and metal-matrix composites for lower temperature applications such as aerospace structures and turbojet fan and compressor blades are under investigation and are discussed. The development of a number of resin systems, including the polyimides and polyphenylquinoxalines, is described and their potential for use at temperatures approaching 315 C (600 F) is indicated. Various molecular modifications that improve processability and/or increase thermal and oxidative resistance of the resins are also described. Structural analysis methods are discussed for determining the stresses and deformations in complex composite systems. Consideration is also given to residual stresses resulting from the curing process and to the foreign object damage problem in fan blade applications.

Signorelli, R. A.↗

NASA NTRS2009

Explicit Finite Element Modeling of Multilayer Composite Fabric for Gas Turbine Engine Containment Systems, Phase II: Ballistic Impact Testing - Part 2

This report summarizes the ballistic impact testing that was conducted to provide validation data for the development of numerical models of blade-out events in fabric containment systems. The ballistic impact response of two different fiber materials - Kevlar(TradeName) 49 and Zylon(TradeName) AS (as spun) was studied by firing metal projectiles into dry woven fabric specimens using a gas gun. The shape, mass, orientation, and velocity of the projectile were varied and recorded. In most cases, the tests were designed so the projectile would perforate the specimen, allowing measurement of the energy absorbed by the fabric. The results for both Zylon and Kevlar presented here represent a useful set of data for the purposes of establishing and validating numerical models to predict the response of fabrics under conditions that simulate those of a jet engine blade-release situation. In addition, some useful empirical observations were made regarding the effects of projectile orientation and the relative performance of the different fabric materials.

Zylon↗

NASA NTRS2020

Alaska Transportation & Infrastructure Identifying Permafrost Subsidence Using NASA Earth Observations to Pinpoint Road and Infrastructure Vulnerability in Fairbanks, Alaska

A rapidly warming Arctic has compromised the structural integrity of critical infrastructure through accelerated permafrost thaw and thermokarst development underlying these areas. Infrastructure, including roads, bridges, and airports across the state of Alaska are particularly at risk, as permafrost underlies ~85% of the state. However, monitoring the impacts of permafrost thaw on infrastructure is largely limited to in situ observations and frequently identified after the damage is evident. In order to assist transportation and infrastructure decision-makers in Alaska, this project identified and quantified areas of surface subsidence near critical infrastructure. Seasonal interferograms were created using Sentinel-1 C-band Synthetic Aperture Radar (SAR) and L-band Uninhabited Aerial Vehicle SAR (UAVSAR) data to identify areas experiencing surface deformation. Additionally, Light Detection and Ranging (LiDAR) datasets were used to validate select interferograms created between 2017 and 2019. Validation of subsidence detection across platforms was performed over a 7x8 sq. kilometer field site for 2017. The strongest relationship in spatial deformation is observed between Sentinel-1 and UAVSAR with a residual root mean square error of 20 mm. These results suggest that both UAVSAR and Sentinel-1 platforms are capable of detecting surface subsidence. The higher resolution of UAVSAR is better able to resolve localized subsidence features of less than 80 meters, but is limited by temporal resolution. In conjunction, UAVSAR and Sentinel-1 can provide complementary spatial and temporal resolutions for subsidence analysis in the absence of in situ data.

DEVELOP Tech Paper↗

NASA NTRS1992

Real-time combining of residual carrier array signals using ML weight estimates

A real-time digital signal combining system for use with array feeds is proposed. The combining system attempts to compensate for signal-to-noise ratio (SNR) loss resulting from antenna deformations induced by gravitational and atmospheric effects. The combining weights are obtained directly from the observed residual carrier samples in each channel using a 'sliding-window' implementation of a maximum-likelihood (ML) parameter estimator. It is shown that with averaging times of about 0.1 s, combining loss for a seven-element array can be limited to about 0.1 dB in a realistic operational environment. This result suggests that the real-time combining system proposed here is capable of recovering virtually all of the signal power captured by the array feed, even in the presence of severe wind gusts and similar disturbances.

Vilnrotter, Victor A.↗

NASA NTRS1981

NASA five-ball fatigue tester: Over 20 years of research

Studies were conducted to determine the effect on rolling-element fatigue life of contact angle, material hardness, chemistry, heat treatment and processing, lubricant type and chemistry, elastohydrodynamic film thickness, deformation and wear, vacuum, and temperature as well as Hertzian and residual stresses. Correlation was established between the results obtained using the five-ball tester and those obtained with full scale rolling-element bearings.

Zaretsky, E. V.↗

NASA NTRS1981

NASA five-ball fatigue tester - Over 20 years of research

The paper reviews, from both a technical and historic perspective, the results of research conducted using the NASA Five-Ball Fatigue Tester. The test rig was conceived by W. J. Anderson in late 1958. The first data was generated in March 1959. Since then a total of approximately 500,000 test hours have been accumulated on a group of eight test rigs which are capable of running 24 hours a day, 7 days a week. Studies have been conducted to determine the effect on rolling-element fatigue life of contact angle, material hardness, chemistry, heat treatment, and processing, lubricant type and chemistry, elastohydrodynamic film thickness, deformation and wear, vacuum, and temperature as well as Hertzian and residual stresses. Correlation was established between the results obtained using the five-ball tester and those obtained with full-scale rolling-element bearings.

Zaretsky, E. V.↗

NASA NTRS1983

Dimensional stability considerations for cryogenic metals

Work performed as part of an effort to identify, and where possible separate out, some of the factors that contribute to dimensional stability in cryogenic wind tunnel models is reported. Initial problems were encountered with two dimensional models made of 15-5 PH stainless steel, which warped significantly after being subjected to cryogenic testing in the 0.3 Meter Transonic Cryogenic Tunnel. Subsequently, an effort was undertaken to investigate the mechanisms that could cause model warpage during cryogenic testing. The two basic mechanisms that can lead to warpage are (1) metallurgical structural instability in which one phase transforms partially or fully into a second phase which has a different crystal structure and volume, and (2) deformation due to the creation, or relief, of unbalanced induced or residual stresses. In the case of the 15-5 PH airfoils, it is highly probable that metallurgical instability was responsible for most of the observed warpage. A particular specimen configuration was established for use in the systematic evaluation of the factors influencing warpage. Preliminary studies of a specimen made of VASCOMAX 200 suggest the possibility of manipulating the stresses in the surface layers by appropriate combinations of milling and grinding steps. This opens up the possibility of correcting or establishing the required surface profile of an airfoil.

Wigley, D. A.↗