Ultrasonic detection and measurement of fatigue cracks in notched specimens
Ultrasonic detection and measurement of fatigue crack propagation in notched specimens of aluminum, titanium, and cobalt alloys and maraging steels
Freche, J. C.↗
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A potential means of using acoustic emission for crack detection under cyclic-load conditions
A preliminary investigation was conducted to assess the feasibility of monitoring acoustic emission signals from fatigue cracks during cyclic bend tests. Plate specimens of 6A1-4V titanium, 2219-T87 aluminum, and 18-Ni maraging steel were tested with and without crack starter notches. It was found that significant acoustic emission signals could be detected in the frequency range from 100 kHz to 400 kHz. Cracks emanating from starter notches were monitored by the ultrasonic pulse-echo technique and periodically measured by micro-optical examination. Methods used to reduce the effects of extraneous noises (i.e., machine noises, fretting) are described. A frequency spectrum analyzer was used to characterize the emissions and to evaluate methods used to acquire the signals (i.e., transducer location, bandwidth selection). The investigation indicated that it was possible to extract meaningful acoustic emission signals in a cyclic bend machine environment.
Vary, A.↗
A potential means of using acoustic emission for crack detection under cyclic-load conditions.
A preliminary investigation was conducted to assess the feasibility of monitoring acoustic emission signals from fatigue cracks during cyclic bend tests. Plate specimens of 6Al-4V titanium, 2219-T87 aluminum, and 18-Ni maraging steel were tested with and without crack starter notches. It was found that significant acoustic emission signals could be detected in the frequency range from 100 to 400 kHz. Cracks emanating from starter notches were monitored by the ultrasonic pulse-echo technique and periodically measured by micro-optical examination. The investigation indicated that it was possible to extract meaningful acoustic emission signals in a cyclic bend machine environment.
Vary, A.↗
The feasibility of ranking material fracture toughness by ultrasonic attenuation measurements
A preliminary study was conducted to assess the feasibility of ultrasonically ranking material fracture toughness. Specimens of two grades of maraging steel for which fracture toughness values were measured were subjected to ultrasonic probing. The slope of the attenuation coefficient versus frequency curve was empirically correlated with the plane strain fracture toughness value for each grade of steel.
Vary, A.↗
Monitoring crack extension in fracture toughness tests by ultrasonics
An ultrasonic method was used to observe the onset of crack extension and to monitor continued crack growth in fracture toughness specimens during three point bend tests. A 20 MHz transducer was used with commercially available equipment to detect average crack extension less than 0.09 mm. The material tested was a 300-grade maraging steel in the annealed condition. A crack extension resistance curve was developed to demonstrate the usefulness of the ultrasonic method for minimizing the number of tests required to generate such curves.
Klima, S. J.↗
The feasibility of ranking material fracture toughness by ultrasonic attenuation measurements
A preliminary study was conducted to assess the feasibility of ultrasonically ranking material fracture toughness. Specimens of two grades of maraging steel for which fracture toughness values were measured were subjected to ultrasonic probing. The slope of the attenuation coefficient vs frequency curve was empirically correlated with the plane strain fracture toughness value for each grade of steel.
Vary, A.↗
Correlations among ultrasonic propagation factors and fracture toughness properties of metallic materials
Empirical evidence was developed to show that a close relation exists among fracture toughness, yield strength, and ultrasonic attenuation properties of metallic materials. The evidence was obtained by ultrasonic probing of specimens of two maraging steels and a titanium alloy. It was concluded that nondestructive ultrasonic methods can be used to indirectly evaluate fracture-related material properties. The results suggest that these nondestructive ultrasonic measurements can also serve as an adjunct to destructive testing, measurement, and analysis of fracture properties.
Vary, A.↗
Correlations among ultrasonic propagation factors and fracture toughness properties of metallic materials
Empirical evidence was developed to show that a close relation exists among fracture toughness, yield strength, and ultrasonic attenuation properties of metallic materials. The evidence was obtained by ultrasonic probing of specimens of two maraging steels and a titanium alloy. It was concluded that nondestructive ultrasonic methods can be used to indirectly evaluate fracture-related material properties. The results suggest that these nondestructive ultrasonic measurements can also serve as an adjunct to destructive testing, measurement, and analysis of fracture properties.
Vary, A.↗
Monitoring crack extension in fracture toughness tests by ultrasonics
An ultrasonic method was used to observe the onset of crack extension and to monitor continued crack growth in fracture toughness specimens during three-point bend tests. A 20-MHz transducer was used with commercially available equipment to detect average crack extension less than 0.09 mm. The material tested was a 300-grade maraging steel in the annealed condition. A crack extension resistance curve was developed to demonstrate the usefulness of the ultrasonic method for minimizing the number of tests required to generate such curves.
Klima, S. J.↗
The relation of the yield stress of high-pressure anvils to the pressure attained at yielding and the ultimate attainable pressure
A sensitive microprofilometer was used to determine the onset of yielding in the anvils of a supported opposed anvil device for the case of 3% cobalt-cemented tungsten carbide as the anvil material. In addition, it is shown how the commencement of yielding in boron carbide pistons, the yield strength being known, can be used to obtain the transition pressure to a conducting phase in gallium phosphide. The transition pressures of bismuth and gallium phosphide are obtained and it is found that these transitions are extremely close to the maximum attainable pressure in, respectively, a maraging steel and a 3% cobalt-cemented tungsten carbide.
Panda, P. C.↗
Development of forward and aft separation bolts for the NASA Space Shuttle solid rocket booster separation system
A program is underway to design, develop, fabricate, and qualify large high-load forward and aft separation bolts for the Space Shuttle; the bolts will serve as attachment between two solid rocket boosters and the external tank. This paper reviews bolt development, with emphasis on the scaling of components, the use of high strength maraging steel for the internal components, and the use of lead as a hydraulic fluid.
Nein, H.↗
A proposed configuration for a stepped specimen to be used in the systematic evaluation of factors influencing warpage in metallic alloys being used for cryogenic wind tunnel models
A proposed configuration for a stepped specimen to be used in the system evaluation of mechanisms that can introduce warpage or dimensional changes in metallic alloys used for cryogenic wind tunnel models is described. Considerations for selecting a standard specimen are presented along with results obtained from an investigation carried out for VASCOMAX 200 maraging steel. Details of the machining and measurement techniques utilized in the investigation are presented. Initial results from the sample of VASCOMAX 200 show that the configuration and measuring techniques are capable of giving quantitative results.
Wigley, D. A.↗
Metallic alloy stability studies
The dimensional stability of candidate cryogenic wind tunnel model materials was investigated. Flat specimens of candidate materials were fabricated and cryo-cycled to assess relative dimensional stability. Existing 2-dimensional airfoil models as well as models in various stages of manufacture were also cryo-cycled. The tests indicate that 18 Ni maraging steel offers the greatest dimensional stability and that PH 13-8 Mo stainless steel is the most stable of the stainless steels. Dimensional stability is influenced primarily by metallurgical transformations (austenitic to martensitic) and manufacturing-induced stresses. These factors can be minimized by utilization of stable alloys, refinement of existing manufacturing techniques, and incorporation of new manufacturing technologies.
Firth, G. C.↗
Operating characteristics of a 0.87 kW-hr flywheel energy storage module
Discussion is given of the design and loss characteristics of 0.87 kW-hr (peak) flywheel energy storage module suitable for aerospace and automotive applications. The maraging steel flywheel rotor, a 46-cm- (18-in-) diameter, 58-kg (128-lb) tapered disk, delivers 0.65 kW-hr of usable energy between operating speeds of 10,000 and 20,000 rpm. The rotor is supported by 20- and 25-mm bore diameter, deep-groove ball bearings, lubricated by a self-replenishing wick type lubrication system. To reduce aerodynamic losses, the rotor housing was evacuated to vacuum levels from 40 to 200 millitorr. Dynamic rotor instabilities uncovered during testing necessitated the use of an elastometric-bearing damper to limit shaft excursions. Spindown losses from bearing, seal, and aerodynamic drag at 50 millitorr typically ranged from 64 to 193 W at 10,000 and 20,000 rpm, respectively. Discharge efficiency of the flywheel system exceeded 96 percent at torque levels greater than 21 percent of rated torque.
Loewenthal, S. H.↗
Operating characteristics of a 0.87 kW-hr flywheel energy storage module
Discussion is given of the design and loss characteristics of 0.87 kW-hr (peak) flywheel energy storage module suitable for aerospace and automotive applications. The maraging steel flywheel rotor, a 46-cm-(18-in-) diameter, 58-kg (128-lb) tapered disk, delivers 0.65 kW-hr of usable energy between operating speeds of 10,000 and 20,000 rpm. The rotor is supported by 20- and 25-mm bore diameter, deep-groove ball bearings, lubricated by a self-replenishing wick type lubrication system. To reduce aerodynamic losses, the rotor housing was evacuated to vacuum levels from 40 to 200 millitorr. Dynamic rotor instabilities uncovered during testing necessitated the use of an elastometric-bearing damper to limit shaft excursions. Spindown losses from bearing, seal, and aerodynamic drag at 50 millitorr typically ranged from 64 to 193 W at 10,000 and 20,000 rpm, respectively. Discharge efficiency of the flywheel system exceeded 96 percent at torque levels greater than 21 percent of rated torque.
Loewenthal, S. H.↗
Design of a unidirectional composite momentum wheel rim
A preliminary study comparing twelve unidirectional-fiber composite systems to five metal materials conventionally used in momentum wheels is presented. Six different fibers are considered in the study: E-Glass, S-Glass, Boron, AS, T300, and Kevlar. Because of the possibility of high momentum requirements, and thus high stresses, only two matrix materials are considered: a high-modulus (HM) and a intermediate-modulus-high-strength (IMHS) matrix. Each of the six fibers are coupled with each of the two matrix materials. In an effort to optimize the composite system, each composite is considered while varying the fiber volume ratio from 0.0 to 0.7 in increments of 0.1. For fiber volume ratios above 0.2, all twelve unidirectional-fiber composite systems meet the study's requirements with higher factors of safety and less mass than the five conventional isotropic (metal) materials. For example, at a fiber volume ratio of 0.6, the Kevlar/IMHS composite system has a safety factor 4.5 times greater than that of a steel (maraging) system and an approximately 10 percent reduction in weight.
Shogrin, Bradley↗
Polynomial Expressions for Estimating Elastic Constants From the Resonance of Circular Plates
Two approaches were taken to make convenient spread sheet calculations of elastic constants from resonance data and the tables in ASTM C1259 and E1876: polynomials were fit to the tables; and an automated spread sheet interpolation routine was generated. To compare the approaches, the resonant frequencies of circular plates made of glass, hardened maraging steel, alpha silicon carbide, silicon nitride, tungsten carbide, tape cast NiO-YSZ, and zinc selenide were measured. The elastic constants, as calculated via the polynomials and linear interpolation of the tabular data in ASTM C1259 and E1876, were found comparable for engineering purposes, with the differences typically being less than 0.5 percent. Calculation of additional v values at t/R between 0 and 0.2 would allow better curve fits. This is not necessary for common engineering purposes, however, it might benefit the testing of emerging thin structures such as fuel cell electrolytes, gas conversion membranes, and coatings when Poisson s ratio is less than 0.15 and high precision is needed.
Salem, Jonathan A.↗
Mars Science Laboratory Drill
This drill (see Figure 1) is the primary sample acquisition element of the Mars Science Laboratory (MSL) that collects powdered samples from various types of rock (from clays to massive basalts) at depths up to 50 mm below the surface. A rotary-percussive sample acquisition device was developed with an emphasis on toughness and robustness to handle the harsh environment on Mars. It is the first rover-based sample acquisition device to be flight-qualified (see Figure 2). This drill features an autonomous tool change-out on a mobile robot, and novel voice-coil-based percussion. The drill comprises seven subelements. Starting at the end of the drill, there is a bit assembly that cuts the rock and collects the sample. Supporting the bit is a subassembly comprising a chuck mechanism to engage and release the new and worn bits, respectively, and a spindle mechanism to rotate the bit. Just aft of that is a percussion mechanism, which generates hammer blows to break the rock and create the dynamic environment used to flow the powdered sample. These components are mounted to a translation mechanism, which provides linear motion and senses weight-on-bit with a force sensor. There is a passive-contact sensor/stabilizer mechanism that secures the drill fs position on the rock surface, and flex harness management hardware to provide the power and signals to the translating components. The drill housing serves as the primary structure of the turret, to which the additional tools and instruments are attached. The drill bit assembly (DBA) is a passive device that is rotated and hammered in order to cut rock (i.e. science targets) and collect the cuttings (powder) in a sample chamber until ready for transfer to the CHIMRA (Collection and Handling for Interior Martian Rock Analysis). The DBA consists of a 5/8-in. (.1.6- cm) commercial hammer drill bit whose shank has been turned down and machined with deep flutes designed for aggressive cutting removal. Surrounding the shank of the bit is a thick-walled maraging steel collection tube allowing the powdered sample to be augured up the hole into the sample chamber. For robustness, the wall thickness of the DBA was maximized while still ensuring effective sample collection. There are four recesses in the bit tube that are used to retain the fresh bits in their bit box. The rotating bit is supported by a back-to-back duplex bearing pair within a housing that is connected to the outer DBA housing by two titanium diaphragms. The only bearings on the drill in the sample flow are protected by a spring-energized seal, and an integrated shield that diverts the ingested powdered sample from the moving interface. The DBA diaphragms provide radial constraint of the rotating bit and form the sample chambers. Between the diaphragms there is a sample exit tube from which the sample is transferred to the CHIMRA. To ensure that the entire collected sample is retained, no matter the orientation of the drill with respect to gravity during sampling, the pass-through from the forward to the aft chamber resides opposite to the exit tube.
Okon, Avi B.↗