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NASA NTRS2004

Testing of Composite Fan Vanes With Erosion-Resistant Coating Accelerated

The high-cycle fatigue of composite stator vanes provided an accelerated life-state prior to insertion in a test stand engine. The accelerated testing was performed in the Structural Dynamics Laboratory at the NASA Glenn Research Center under the guidance of Structural Mechanics and Dynamics Branch personnel. Previous research on fixturing and test procedures developed at Glenn determined that engine vibratory conditions could be simulated for polymer matrix composite vanes by using the excitation of a combined slip table and electrodynamic shaker in Glenn's Structural Dynamics Laboratory. Bench-top testing gave researchers the confidence to test the coated vanes in a full-scale engine test.

Bowman, Cheryl L.↗

NASA NTRS2005

Advanced Vibration Analysis Tool Developed for Robust Engine Rotor Designs

The primary objective of this research program is to develop vibration analysis tools, design tools, and design strategies to significantly improve the safety and robustness of turbine engine rotors. Bladed disks in turbine engines always feature small, random blade-to-blade differences, or mistuning. Mistuning can lead to a dramatic increase in blade forced-response amplitudes and stresses. Ultimately, this results in high-cycle fatigue, which is a major safety and cost concern. In this research program, the necessary steps will be taken to transform a state-of-the-art vibration analysis tool, the Turbo- Reduce forced-response prediction code, into an effective design tool by enhancing and extending the underlying modeling and analysis methods. Furthermore, novel techniques will be developed to assess the safety of a given design. In particular, a procedure will be established for using natural-frequency curve veerings to identify ranges of operating conditions (rotational speeds and engine orders) in which there is a great risk that the rotor blades will suffer high stresses. This work also will aid statistical studies of the forced response by reducing the necessary number of simulations. Finally, new strategies for improving the design of rotors will be pursued.

Min, James B.↗

NASA NTRS2011

On the Response of a Nonlinear Structure to High Kurtosis Non-Gaussian Random Loadings

This paper is a follow-on to recent work by the authors in which the response and high-cycle fatigue of a nonlinear structure subject to non-Gaussian loadings was found to vary markedly depending on the nature of the loading. There it was found that a non-Gaussian loading having a steady rate of short-duration, high-excursion peaks produced essentially the same response as would have been incurred by a Gaussian loading. In contrast, a non-Gaussian loading having the same kurtosis, but with bursts of high-excursion peaks was found to elicit a much greater response. This work is meant to answer the question of when consideration of a loading probability distribution other than Gaussian is important. The approach entailed nonlinear numerical simulation of a beam structure under Gaussian and non-Gaussian random excitations. Whether the structure responded in a Gaussian or non-Gaussian manner was determined by adherence to, or violations of, the Central Limit Theorem. Over a practical range of damping, it was found that the linear response to a non-Gaussian loading was Gaussian when the period of the system impulse response is much greater than the rate of peaks in the loading. Lower damping reduced the kurtosis, but only when the linear response was non-Gaussian. In the nonlinear regime, the response was found to be non-Gaussian for all loadings. The effect of a spring-hardening type of nonlinearity was found to limit extreme values and thereby lower the kurtosis relative to the linear response regime. In this case, lower damping gave rise to greater nonlinearity, resulting in lower kurtosis than a higher level of damping.

Rizzi, Stephen A.↗

NASA NTRS2003

Analyzing Aeroelasticity in Turbomachines

ASTROP2-LE is a computer program that predicts flutter and forced responses of blades, vanes, and other components of such turbomachines as fans, compressors, and turbines. ASTROP2-LE is based on the ASTROP2 program, developed previously for analysis of stability of turbomachinery components. In developing ASTROP2- LE, ASTROP2 was modified to include a capability for modeling forced responses. The program was also modified to add a capability for analysis of aeroelasticity with mistuning and unsteady aerodynamic solutions from another program, LINFLX2D, that solves the linearized Euler equations of unsteady two-dimensional flow. Using LINFLX2D to calculate unsteady aerodynamic loads, it is possible to analyze effects of transonic flow on flutter and forced response. ASTROP2-LE can be used to analyze subsonic, transonic, and supersonic aerodynamics and structural mistuning for rotors with blades of differing structural properties. It calculates the aerodynamic damping of a blade system operating in airflow so that stability can be assessed. The code also predicts the magnitudes and frequencies of the unsteady aerodynamic forces on the airfoils of a blade row from incoming wakes. This information can be used in high-cycle fatigue analysis to predict the fatigue lives of the blades.

Reddy, T. S. R.↗

NASA NTRS1995

Probabilistic material strength degradation model for Inconel 718 components subjected to high temperature, high-cycle and low-cycle mechanical fatigue, creep and thermal fatigue effects

This report presents the results of both the fifth and sixth year effort of a research program conducted for NASA-LeRC by The University of Texas at San Antonio (UTSA). The research included on-going development of methodology for a probabilistic material strength degradation model. The probabilistic model, in the form of a postulated randomized multifactor equation, provides for quantification of uncertainty in the lifetime material strength of aerospace propulsion system components subjected to a number of diverse random effects. This model is embodied in the computer program entitled PROMISS, which can include up to eighteen different effects. Presently, the model includes five effects that typically reduce lifetime strength: high temperature, high-cycle mechanical fatigue, low-cycle mechanical fatigue, creep and thermal fatigue. Statistical analysis was conducted on experimental Inconel 718 data obtained from the open literature. This analysis provided regression parameters for use as the model's empirical material constants, thus calibrating the model specifically for Inconel 718. Model calibration was carried out for five variables, namely, high temperature, high-cycle and low-cycle mechanical fatigue, creep and thermal fatigue. Methodology to estimate standard deviations of these material constants for input into the probabilistic material strength model was developed. Using an updated version of PROMISS, entitled PROMISS93, a sensitivity study for the combined effects of high-cycle mechanical fatigue, creep and thermal fatigue was performed. Then using the current version of PROMISS, entitled PROMISS94, a second sensitivity study including the effect of low-cycle mechanical fatigue, as well as, the three previous effects was performed. Results, in the form of cumulative distribution functions, illustrated the sensitivity of lifetime strength to any current value of an effect. In addition, verification studies comparing a combination of high-cycle mechanical fatigue and high temperature effects by model to the combination by experiment were conducted. Thus, for Inconel 718, the basic model assumption of independence between effects was evaluated. Results from this limited verification study strongly supported this assumption.

Bast, Callie C.↗

NASA NTRS1995

Probabilistic Material Strength Degradation Model for Inconel 718 Components Subjected to High Temperature, High-Cycle and Low-Cycle Mechanical Fatigue, Creep and Thermal Fatigue Effects

The development of methodology for a probabilistic material strength degradation is described. The probabilistic model, in the form of a postulated randomized multifactor equation, provides for quantification of uncertainty in the lifetime material strength of aerospace propulsion system components subjected to a number of diverse random effects. This model is embodied in the computer program entitled PROMISS, which can include up to eighteen different effects. Presently, the model includes five effects that typically reduce lifetime strength: high temperature, high-cycle mechanical fatigue, low-cycle mechanical fatigue, creep and thermal fatigue. Results, in the form of cumulative distribution functions, illustrated the sensitivity of lifetime strength to any current value of an effect. In addition, verification studies comparing predictions of high-cycle mechanical fatigue and high temperature effects with experiments are presented. Results from this limited verification study strongly supported that material degradation can be represented by randomized multifactor interaction models.

Bast, Callie C.↗

NASA NTRS1974

Examination of the influence of coatings on thin superalloy sections. Volume 1: Description and analysis

The effects of an aluminide coating and of section thickness were investigated on two cast nickel-base superalloys. Cast section thickness ranged from 0.038 cm to 0.15 cm. Simulated engine exposures in a jet fuel burner rig with cyclic air cooling were studied. The effects of surface machining before coating and re-machining and re-coating after exposures were examined. The properties evaluated included tensile strength, stress rupture, high-cycle mechanical fatigue, and thermal fatigue. A metallurgical analysis was made of the microstructures of the coated and uncoated alloy.

Kaufman, M.↗

NASA NTRS2000

Effect of Crystal Orientation on Analysis of Single-Crystal, Nickel-Based Turbine Blade Superalloys

High-cycle fatigue-induced failures in turbine and turbopump blades is a pervasive problem. Single-crystal nickel turbine blades are used because of their superior creep, stress rupture, melt resistance, and thermomechanical fatigue capabilities. Single-crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant and complicating factor. A fatigue failure criterion based on the maximum shear stress amplitude on the 24 octahedral and 6 cube slip systems is presented for single-crystal nickel superalloys (FCC crystal). This criterion greatly reduces the scatter in uniaxial fatigue data for PWA 1493 at 1,200 F in air. Additionally, single-crystal turbine blades used in the Space Shuttle main engine high pressure fuel turbopump/alternate turbopump are modeled using a three-dimensional finite element (FE) model. This model accounts for material orthotrophy and crystal orientation. Fatigue life of the blade tip is computed using FE stress results and the failure criterion that was developed. Stress analysis results in the blade attachment region are also presented. Results demonstrate that control of crystallographic orientation has the potential to significantly increase a component's resistance to fatigue crack growth without adding additional weight or cost.

Swanson, G. R.↗

NASA NTRS2011

A New High-Speed, High-Cycle, Gear-Tooth Bending Fatigue Test Capability

A new high-speed test capability for determining the high cycle bending-fatigue characteristics of gear teeth has been developed. Experiments were performed in the test facility using a standard spur gear test specimens designed for use in NASA Glenn s drive system test facilities. These tests varied in load condition and cycle-rate. The cycle-rate varied from 50 to 1000 Hz. The loads varied from high-stress, low-cycle loads to near infinite life conditions. Over 100 tests were conducted using AISI 9310 steel spur gear specimen. These results were then compared to previous data in the literature for correlation. Additionally, a cycle-rate sensitivity analysis was conducted by grouping the results according to cycle-rate and comparing the data sets. Methods used to study and verify load-path and facility dynamics are also discussed.

Stringer, David B.↗

NASA NTRS1974

Investigation of fatigue strength of multilayer advanced fiber composites

The analytical characterization of a multilayer fiber composite plate (without hole) was accomplished for both static and dynamic loading conditions using the finite difference technique. Thornel 300/5208 composites with and without holes were subjected to static and tensile fatigue testing. Five (5) fiber orientations were submitted to test. Tensile fatigue testing also included three (3) loading conditions and two (2) frequencies. The low-cycle test specimens demonstrated a shorter tensile fatigue life than the high-cycle test specimens. Failure surfaces demonstrated effect of testing conditions. Secondary failure mechanisms, such as: delamination, fiber breakage, and edge fiber delamination were present. Longitudinal delamination between plies also occurred in these specimens.

Thornton, H. R.↗

NASA NTRS1979

An oxide dispersion strengthened alloy for gas turbine blades

The strength of the newly developed alloy MA-6000E is derived from a nickel alloy base, an enlongated grain structure, naturally occurring precipitates of gamma prime, and an artificial distribution of extremely fine, stable oxide particles. Its composition is Ni-15% Cr-2% Mo-2% Ta-4% W-4.5% Al-2.5% Ti-0.15% Zr-0.05% C-0.01% B-1.1% Y2O3. It exhibits strength of a conventional nickel-base alloy at 1400 F, but is quite superior at 2000 F. Its shear strength is relatively low, necessitating consideration of special joining procedures. Its high-cycle, low-cycle, and thermal fatigue properties are excellent. The relationship between alloy micro-structure and properties is discussed.

Glasgow, T. K.↗

NASA NTRS1993

Effect of mission cycling on the fatigue performance of SiC-coated carbon-carbon composites

The effects of thermal and pressure cycling on the fatigue performance of carbon-carbon composites, and the influence of mission cycling on these effects, were investigated by subjecting both virgin and mission-cycled two-dimensional specimens of SiC-coated carbon-carbon composites to fatigue tests, conducted at room temperature in three-point bending, with a stress ratio of 0.2 and a frequency of 1 Hz. It was found that the fatigue strength of C-C composites is high (about 90 percent of the ultimate flexural strength), but decreased with the mission cycling. The lowering of the fatigue strength with mission cycling is attributed to the increase in interfacial bond strength due to thermal and pressure cycling of the material. The already high sensitivity of C-C composites to stress during cyclic loading increases further with the amount of mission cycling. Results of NDE suggest that the damage growth in virgin C-C, in the high-cycle range, is slow at the initial stage of the cyclic life, but propagates rapidly after certain threshold cycles of the fatigue life.

Mahfuz, H.↗

NASA NTRS1996

Structures Division 1994 Annual Report

The NASA Lewis Research Center Structures Division is an international leader and pioneer in developing new structural analysis, life prediction, and failure analysis related to rotating machinery and more specifically to hot section components in air-breathing aircraft engines and spacecraft propulsion systems. The research consists of both deterministic and probabilistic methodology. Studies include, but are not limited to, high-cycle and low-cycle fatigue as well as material creep. Studies of structural failure are at both the micro- and macrolevels. Nondestructive evaluation methods related to structural reliability are developed, applied, and evaluated. Materials from which structural components are made, studied, and tested are monolithics and metal-matrix, polymer-matrix, and ceramic-matrix composites. Aeroelastic models are developed and used to determine the cyclic loading and life of fan and turbine blades. Life models are developed and tested for bearings, seals, and other mechanical components, such as magnetic suspensions. Results of these studies are published in NASA technical papers and reference publication as well as in technical society journal articles. The results of the work of the Structures Division and the bibliography of its publications for calendar year 1994 are presented.

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NASA NTRS1997

Structures Division

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