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At least 73 records · Page 4

Cracking characteristics of a habitable module pressure wall following orbital debris penetration

All long-duration spacecraft in low-earth-orbit are subject to high speed impacts by meteoroids and pieces of orbital debris. The threat of damage from such impacts is a significant design consideration in the development of long duration earth-orbiting spacecraft. This report presents the results of a study whose objective was to develop an empirical model to predict the magnitude of the various cracking and through-hole creation phenomena accompanying a habitable module penetration. The significance of the work performed is that the model predictions can be fed directly into a survivability analysis to determine whether or not module unzipping would occur under a specific set of impact conditions. The likelihood of module unzipping over a structure's lifetime can also be determined in such an analysis. In addition, effective hole size predictions can be used as part of a survivability analysis to determine the time available for module evacuation prior to the onset of incapacitation due to air loss. Some of the phenomena considered include maximum petal length, maximum tip-to-tip crack distance, depth of petal deformation, number of cracks formed, orientation of the maximum tip-to-tip distance with respect to the inner wall grain direction, and the effective inner wall hole diameter.

Schonberg, William P.↗

A probabilistic model of brittle crack formation

Probability of a brittle crack formation in an elastic solid with fluctuating strength is considered. A set Omega of all possible crack trajectories reflecting the fluctuation of the strength field is introduced. The probability P(X) that crack penetration depth exceeds X is expressed as a functional integral over Omega of a conditional probability of the same event taking place along a particular path. Various techniques are considered to evaluate the integral. Under rather nonrestrictive assumptions, the integral is reduced to solving a diffusion-type equation. A new characteristic of fracture process, 'crack diffusion coefficient', is introduced. An illustrative example is then considered where the integration is reduced to solving an ordinary differential equation. The effect of the crack diffusion coefficient and of the magnitude of strength fluctuations on probability density of crack penetration depth is presented. Practical implications of the proposed model are discussed.

Chudnovsky, A.↗

The crack-contact and the free-end problem for a strip under residual stress

The plane problem for an infinite strip with two edge cracks under a given state of residual stress is considered. The residual stress is compressive near and at the surfaces and tensile in the interior of the strip. If the crack is deep enough to penetrate into the tensile zone, then the problem is one of crack-contact where the depth of the contact area is an unknown which depends on the crack depth and the residual stress profile. The problem has applications to the static fatigue of glass plates and is solved for three typical residual-stress profiles. In the limiting case of the crack's crossing the entire plate thickness, the problem becomes a stressfree end problem for a semiinfinite strip under a given residual-stress state away from the end. This is a typical stress diffusion problem in which decay behavior of the residual stress near and the nature of the normal displacement at the end of the semiinfinite strip are of special interest. For two typical residual-stress states the solution is obtained, and some numerical results are given.

Bakioglu, M.↗

Scattering of ultrasonic wave by cracks in a plate

A hybrid numerical method combining finite elements and the boundary integral representation is used to investigate the transient scattering of ultrasonic waves by a crack in a plate. The incident wave models the guided waves generated by a steel ball impact on the plate. Two surface-breaking cracks and one subsurface crack are studied here. The results show that the location and depth of cracks have measurable effects on the surface responses in time and frequency domains. Also, the scattered fields have distinct differences in the three cases.

Liu, S. W.↗

Optimization of overhang printing in ceramic binder jetting additive manufacturing

Cylindrical-shaped horizontally-hanging overhangs with different heights on a solid cubic body were printed via binder jetting additive manufacturing with sililcon carbide powder feedstock. Cracking on the overhang neck and sagging on the overhang body were observed both pre- and post-curing, especially on printed design with a smaller particle size of 10 μm. Here, it was found that the width of cracking and depth of sagging were dependent on the height relative to the solid body in the powder bed, and elevated position of overhang with large volume of underneath loose powder led to increased extend of cracking and sagging. Overhang diameter and weight were varied, which were found with no apparent effects on its deformation extend. To mitigate cracking and sagging, contactless support was designed and tested, which could significantly improve the overhang stability and avoid any overhang deformations. Support gap and support distance were studied for their effects on support capability. The printing processes with and without contactless support were simulated by a finite element modeling approach to understand the stress distribution and evolution of the overhang structures, which revealed stress concentrations on the upper neck point of the designed overhang.

Binder jetting↗

Corrosion and corrosion fatigue of airframe aluminum alloys

Localized corrosion and corrosion fatigue crack nucleation and growth are recognized as degradation mechanisms that effect the durability and integrity of commercial transport aircraft. Mechanically based understanding is needed to aid the development of effective methodologies for assessing durability and integrity of airframe components. As a part of the methodology development, experiments on pitting corrosion, and on corrosion fatigue crack nucleation and early growth from these pits were conducted. Pitting was found to be associated with constituent particles in the alloys and pit growth often involved coalescence of individual particle-nucleated pits, both laterally and in depth. Fatigue cracks typically nucleated from one of the larger pits that formed by a cluster of particles. The size of pit at which fatigue crack nucleates is a function of stress level and fatigue loading frequency. The experimental results are summarized, and their implications on service performance and life prediction are discussed.

Chen, G. S.↗

Durability and life prediction modeling in polyimide composites

Sudden appearance of cracks on a macroscopically smooth surface of brittle materials due to cooling or drying shrinkage is a phenomenon related to many engineering problems. Although conventional strength theories can be used to predict the necessary condition for crack appearance, they are unable to predict crack spacing and depth. On the other hand, fracture mechanics theory can only study the behavior of existing cracks. The theory of crack initiation can be summarized into three conditions, which is a combination of a strength criterion and laws of energy conservation, the average crack spacing and depth can thus be determined. The problem of crack initiation from the surface of an elastic half plane is solved and compares quite well with available experimental evidence. The theory of crack initiation is also applied to concrete pavements. The influence of cracking is modeled by the additional compliance according to Okamura's method. The theoretical prediction by this structural mechanics type of model correlates very well with the field observation. The model may serve as a theoretical foundation for future pavement joint design. The initiation of interactive cracks of quasi-brittle material is studied based on a theory of cohesive crack model. These cracks may grow simultaneously, or some of them may close during certain stages. The concept of crack unloading of cohesive crack model is proposed. The critical behavior (crack bifurcation, maximum loads) of the cohesive crack model are characterized by rate equations. The post-critical behavior of crack initiation is also studied.

Binienda, Wieslaw K.↗

The Crack-contact and the Free End Problem for a Strip Under Residual Stress

The plane problem for an infinite strip with two edge cracks under a given state of residual stress is considered. The residual stress is compressive near and at the surfaces and tensile in the interior of the strip. If the crack is deep enough to penetrate into the tensile zone, then the problem is one of crack-contact problem in which the depth of the contact area is an unknown which depends on the crack depth and the residual stress profile. The problem has applications to the static fatigue of glass plates and is solved for three typical residual stress profiles. In the limiting case of the crack crossing the entire plate thickness, the problem becomes a stress-free end problem for a semi-infinite strip under a given residual stress state away from the end. This is a typical stress diffusion problem in which decay behavior of the residual stress near and the nature of the normal displacement at the end of the semi-infinite strip are of special interest. For two typical residual stress states the solution is obtained, and some numerical results are given.

Bakioglu, M.↗

Simulated impact damage in a thick graphite/epoxy laminate using spherical indenters

A study was made to determine the extent of fiber damage caused by low-velocity impact of spherical impactors to a very thick graphite/epoxy laminate. The laminate was cut from a filament wound case being developed for the Space Shuttle solid rocket motors. The case was wound using a wet process with AS4W graphite fiber and HBRF-55A epoxy. Impacts were simulated under quasi-static conditions by pressing hemispherically shaped indenters against the laminate at different locations. The contact force and indenter diameter were varied from location to location. The forces were chosen for each indenter diameter to produce contact pressures below and above that required to initiate damage. After the forces were applied, the laminate was cut into smaller pieces so that each piece contained a test site. The pieces were then deplied and the individual plies examined to determine the extent of fiber damage. Broken fibers were found in the outer layers directly beneath the contact site. The locus of broken fibers in each layer resembled a crack normal to the direction of the fibers. The maximum length and depth of the cracks increased with increasing contact pressure and indenter diameter. The internal stresses in the laminate were calculated using Hertz's law and Love's solution for pressure applied on part of the boundary of a semi-infinite body. The maximum length and depth of the cracks were predicted using a maximum shear stress criterion. Predictions and measurements were in good agreement.

Poe, C. C., Jr.↗

Procedure for Automated Eddy Current Crack Detection in Thin Titanium Plates

This procedure provides the detailed instructions for conducting Eddy Current (EC) inspections of thin (5-30 mils) titanium membranes with thickness and material properties typical of the development of Ultra-Lightweight diaphragm Tanks Technology (ULTT). The inspection focuses on the detection of part-through, surface breaking fatigue cracks with depths between approximately 0.002" and 0.007" and aspect ratios (a/c) of 0.2-1.0 using an automated eddy current scanning and image processing technique.

Wincheski, Russell A.↗

Simulated impact damage in a thick graphite/epoxy laminate using spherical indenters

The extent of fiber damage due to low-velocity impacts was determined for very thick graphite/epoxy laminates. The impacts were simulated by pressing spherical indenters against the laminates. After the forces were applied, the laminate was cut into smaller pieces so that each piece contained a test site. Then the pieces were deplied and the individual plies were examined to determine the extent of fiber damage. Broken fibers were found in the outer layers directly beneath the contact site. The locus of broken fibers resembled cracks. The cracks were more or less oriented in the direction of the fibers in the contiguous layers. The maximum length and depth of the cracks increased with increasing contact pressure and indenter diameter. The length and depth of the cracks were also predicted using maximum compression and shear stress criteria. The internal stresses were calculated using Hertz's law and Love's solution for pressure applied on part of the boundary of a semi-infinite body. The predictions and measurements were in good agreement.

Poe, C. C., Jr.↗

Thermal High- and Low-Cycle Fatigue Behavior of Thick Thermal Barrier Coating Systems

Ceramic thermal barrier coatings have received increasing attention for advanced gas turbine and diesel engine applications because of their ability to provide thermal insulation to engine components. However, the durability of these coatings under the severe thermal cycling conditions encountered in a diesel engine (ref. 1) still remains a major issue. In this research at the NASA Lewis Research Center, a high-power laser was used to investigate the thermal fatigue behavior of a yttria-stabilized zirconia coating system under simulated diesel engine conditions. The mechanisms of fatigue crack initiation and propagation, and of coating failure under complex thermal low-cycle fatigue (LCF, representing stop/start cycles) and thermal high-cycle fatigue (HCF, representing operation at 1300 rpm) are described. Continuous wave and pulse laser modes were used to simulate pure LCF and combined LCF/HCF, respectively (ref. 2). The LCF mechanism was found to be closely related to the coating sintering and creep at high temperatures. These creep strains in the ceramic coating led to a tensile stress state during cooling, thus providing the major driving force for crack growth under LCF conditions. The combined LCF/HCF tests induced more severe coating surface cracking, microspallation, and accelerated crack growth than did the pure LCF test. HCF thermal loads also facilitated lateral crack branching and ceramic/bond coat interface delaminations. HCF is associated with the cyclic stresses originating from the high-frequency temperature fluctuation at the ceramic coating surface. The HCF thermal loads act on the crack by a wedging mechanism (ref. 1), resulting in continuous crack growth at temperature. The HCF stress intensity factor amplitude increases with the interaction depth and temperature swing, and decreases with the crack depth. HCF damage also increases with the thermal expansion coefficient and the Young's modulus of the ceramic coating (refs. 1 and 3).

Miller, Robert A.↗

Seeding Cracks Using a Fatigue Tester for Accelerated Gear Tooth Breaking

This report describes fatigue-induced seeded cracks in spur gears and compares them to cracks created using a more traditional seeding method, notching. Finite element analysis (FEA) compares the effective compliance of a cracked tooth to the effective compliance of a notched tooth where the crack and the notch are of the same depth. In this analysis, cracks are propagated to the desired depth using FRANC2D and effective compliances are computed in ANSYS. A compliance-based feature for detecting cracks on the fatigue tester is described. The initiated cracks are examined using both nondestructive and destructive methods. The destructive examination reveals variability in the shape of crack surfaces.

Nenadic, Nenad G.↗

Stress intensity factors for large aspect ratio surface and corner cracks at a semi-circular notch in a tension specimen

Stress intensity factor solutions for semielliptic surface and quarter-elliptic corner cracks emanating from a semicircular notch in a tension specimen are presented. A three-dimensional finite-element analysis in conjunction with the equivalent domain integral was used to calculate stress intensity factors (SIF). SIF solutions for surface or corner crack (crack length to depth ratio of 2) at a notch are presented for a wide range of crack sizes and notch radii. Results showed that the SIF are larger for larger crack lengths and for larger notch radii. The SIF are nearly constant all along the crack front for deep surface cracks and for all corner cracks analysed.

Shivakumar, K. N.↗

Guidelines for Mapping Reliably Detectable Dye Penetrant Crack Size at External Corners with Fillet Radii

The technical memorandum addresses some concerns with dye penetrant crack sizes stated in Table 1 (and Table 2) of NASA-STD-5009B. Table 1 corner crack size of a = 0.100” and c = 0.150” is reasoned to be larger than it should be based on the original Standard dye penetrant qualification. In the original Standard dye penetrant qualification, surface crack size with depth a = 0.075” x length 2c = 0.150” was qualified with minimum 90% Probability of Detection (POD) with 95% confidence (conf.). No corner crack size was qualified by direct POD testing in original dye penetrant qualification. Standard dye penetrant detectable crack size for radiused corner is not addressed in NASA-STD-5009B.

Dye Penetrant Testing↗

Microscopic evaluation of a polyimide (PMR-15)-graphite composite

An effort to evaluate the high temperature performance of a polyimide (PMR-15)-graphite composite which consists of several plies of woven strands of carbon fibers was undertaken. The longterm effect of high temperature on the dry material was studied by exposing polished test specimens of 473 F in a oven for nearly 400 hours. Periodically the specimens were removed and observed microscopically. Gradually surface cracks began to appear and the number of cracks increased over time. At the conclusion of the exposure the specimens were graudually ground down and observed in order to determine the depth of the cracks into the interior of the material. This procedure was repeated at an exposure temperature of 550 F.

Fedderly, J. J.↗

Surface crack growth in fiber composites

The results of an experimental study of damage extension and failure in glass and graphite/epoxy laminates containing partially through-thickness surface cracks are presented. The laminates studied are divided between those containing four plies, 90/0/0/90, 15/-15/-15/15, and 45/-45/-45/45, and those containing 12-16 plies of the general configurations 0/90, + or - 45, and 0/+ or - 60. Most of the results are for surface cracks of various lengths and several depths. Stable damage extension in laminates containing surface cracks is predominantly delamination between plies, and tends to be much more extensive prior to failure than is the case with through-thickness cracks, resulting in approximately notch-insensitive behavior in most cases. A greater tendency for notch-sensitive behavior is found for 0/90 graphite/epoxy laminates for which stable damage extension is more limited. The rate of damage extension with increasing applied stress depends upon the composite system and ply configuration as well as the crack length and depth. An approximate semiempirical method is presented for estimating the growth rate of large damage-regions.

Im, J.↗

Leak-tight crack repair for 304L stainless steel using friction surfacing

Here, friction surfacing (FS) was investigated as a method for sealing 50 μm wide thru-cracks in 3-mm-thick 304L stainless steel (304L) plate. Friction surfacing was performed using two sizes of 304L consumable rod, with diameters of 9.52 mm and 12.7 mm, on two substrate conditions (clean and oxidized). Friction surfacing was able to deposit a 600 μm thick coating and repair cracks to a depth of 100 μm - 200 μm below the original surface, when using the 12.7-mm-diameter consumable rod for both substrate conditions. Helium leak rates of 10 -10 atm-cc/s were achieved on crack repairs, designating them as leak-tight by the ANSI N14.5 standard. Optical and scanning electron microscopy were used to investigate the coating microstructure and bond interfaces. In this study, the 12.7-mm-diameter rod performed better with disruption of the oxide layer on the oxidized substrate and providing a more homogenous coating. Mechanical properties of the coated samples were evaluated by performing micro-indentation, tensile, bending, and adhesion testing. Higher hardness in the coatings was observed due to the fine equiaxed grains resulting from dynamic recrystallization. Complete consolidation of plastically deformed material on the substrate and a strong diffusion bond across the interface was observed. This was reflected in tensile and bending properties of the FS coatings being comparable to those of uncoated specimen. No delamination of the FS coating was observed during adhesion testing. The results demonstrate that friction surfacing is a viable option to seal cracks in stainless steels.

36 MATERIALS SCIENCE↗