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NASA NTRS1989

Fiber optic strain measurements in filament-wound graphite-epoxy tubes containing embedded fibers

Filament-wound graphite-epoxy tubes fabricated with embedded fiber optic sensors were tested at NASA Langley Research Center to evaluate the feasibility of monitoring stress with a fiber optic technique. Resistance strain gauges were attached to the tubes to measure strain at four locations along the tubes. Both static and dynamic strain measurements were made with an excellent agreement between the embedded fiber optic strain sensor and the strain gauges. The results indicate that fiber optic sensors embedded in composites may be useful as the sensing component of smart structures.

Rogowski, R. S.↗

NASA NTRS1996

Verification of Experimental Techniques for Flow Surface Determination

The concept of a yield surface is central to the mathematical formulation of a classical plasticity theory. However, at elevated temperatures, material response can be highly time-dependent, which is beyond the realm of classical plasticity. Viscoplastic theories have been developed for just such conditions. In viscoplastic theories, the flow law is given in terms of inelastic strain rate rather than the inelastic strain increment used in time-independent plasticity. Thus, surfaces of constant inelastic strain rate or flow surfaces are to viscoplastic theories what yield surfaces are to classical plasticity. The purpose of the work reported herein was to validate experimental procedures for determining flow surfaces at elevated temperatures. Since experimental procedures for determining yield surfaces in axial/torsional stress space are well established, they were employed -- except inelastic strain rates were used rather than total inelastic strains. In yield-surface determinations, the use of small-offset definitions of yield minimizes the change of material state and allows multiple loadings to be applied to a single specimen. The key to the experiments reported here was precise, decoupled measurement of axial and torsional strain. With this requirement in mind, the performance of a high-temperature multi-axial extensometer was evaluated by comparing its results with strain gauge results at room temperature. Both the extensometer and strain gauges gave nearly identical yield surfaces (both initial and subsequent) for type 316 stainless steel (316 SS). The extensometer also successfully determined flow surfaces for 316 SS at 650 C. Furthermore, to judge the applicability of the technique for composite materials, yield surfaces were determined for unidirectional tungsten/Kanthal (Fe-Cr-Al).

Lissenden, Cliff J.↗

NASA NTRS1965

Residual stresses in 17-4 PH steel

Effects of heat treatment on residual stress of 17-4 PH steel, and influence of stress on dimensional integrity of strain gauge balances

STEEL↗

NASA NTRS2003

Strength Differential Measured in Inconel 718: Effects of Hydrostatic Pressure Studied

Aeropropulsion components, such as disks, blades, and shafts, are commonly subjected to multiaxial stress states at elevated temperatures. Experimental results from loadings as complex as those experienced in service are needed to help guide the development of accurate viscoplastic, multiaxial deformation models that can be used to improve the design of these components. During a recent study on multiaxial deformation (ref. 1) on a common aerospace material, Inconel 718, it was shown that the material in the aged state exhibits a strength differential effect (SDE), whereby the uniaxial compressive yield and subsequent flow behavior are significantly higher than those in uniaxial tension. Thus, this material cannot be described by a standard von Mises yield formulation. There have been other formulations postulated (ref. 2) that involve other combinations of the stress invariants, including the effect of hydrostatic stress. The question remained as to which invariants are necessary in the flow model. To capture the physical mechanisms occurring during deformation and reflect them in the plasticity formulation, researchers examined the flow of Inconel 718 under various amounts of hydrostatic stress to determine whether or not hydrostatic stress is needed in the formulation. Under NASA Grant NCC3-464, monitored by the NASA Glenn Research Center, a series of tensile tests were conducted at Case Western Reserve University on aged (precipitation hardened) Inconel 718 at 650 C and with superimposed hydrostatic pressure. Dogbone shaped tensile specimens (3-mm-diameter gauge by 16-mm gauge length) and cylindrical compression specimens (3-mm-diameter gauge by 6-mm gauge length) were strain gauged and loaded in a high-pressure testing apparatus. Hydrostatic pressures were obtained with argon and ranged from 210 to 630 MPa. The aged Inconel 718 showed a pronounced difference in the tension and compression yield strength (i.e., an SDE), as previously observed. Also, there were no significant effects of hydrostatic pressure on either the tensile and compressive yield strength (see the graph) or on the magnitude of the SDE. This behavior is not consistent with the pressure-dependent theory of the SDE, which postulates that the SDE is associated with pressure-dependent and/or internal friction dependent deformation associated with non-Schmid effects at the crystal level (refs. 3 and 4). Flow in Inconel 718 appears to be independent of hydrostatic pressure, suggesting that this invariant may be removed from the phenomenological constitutive model. As part of an ongoing effort to develop advanced constitutive models, Glenn s Life Prediction Branch coordinated this work with that of research on the multiaxial deformation behavior of Inconel 718 being conducted at Pennsylvania State University under NASA Grant NCC597.

Lewandowski, John J.↗

NASA NTRS2003

Noninterference Systems Developed for Measuring and Monitoring Rotor Blade Vibrations

In the noninterference measurement of blade vibrations, a laser light beam is transmitted to the rotor blade tips through a single optical fiber, and the reflected light from the blade tips is collected by a receiving fiber-optic bundle and conducted to a photodetector. Transmitting and receiving fibers are integrated in an optical probe that is enclosed in a metal tube which also houses a miniature lens that focuses light on the blade tips. Vibratory blade amplitudes can be deduced from the measurement of the instantaneous time of arrival of the blades and the knowledge of the rotor speed. The in-house noninterference blade-vibration measurement system was developed in response to requirements to monitor blade vibrations in several tests where conventional strain gauges could not be installed or where there was a need to back up strain gauges should critical gauges fail during the test. These types of measurements are also performed in the aircraft engine industry using proprietary in-house technology. Two methods of measurement were developed for vibrations that are synchronous with a rotor shaft. One method requires only one sensor; however, it is necessary to continuously record the data while the rotor is being swept through the resonance. In the other method, typically four sensors are employed and the vibratory amplitude is deduced from the data by performing a least square fit to a harmonic function. This method does not require continuous recording of data through the resonance and, therefore, is better suited for monitoring. The single-probe method was tested in the Carl facility at the Wright- Patterson Air Force Base, and the multiple-probe method was tested in NASA Glenn Research Center's Spin Rig facility, which uses permanent magnets to excite synchronous vibrations. Representative results from this test are illustrated in the bar chart. Nonsynchronous vibrations were measured online during testing of the Quiet High Speed Fan in Glenn s 9- by 15-Foot Low-Speed Wind Tunnel. Three sensors were employed, enabling a reconstruction of the vibratory patterns at the leading and trailing edges at the tip span, as well as a determination of vibratory amplitudes for every blade.

Kurkov, Anatole P.↗

NASA NTRS1979

Determination of the technical constants of laminates in oblique directions

An off-axis tensile test theory based on Hooke's Law is applied to glass fiber reinforced laminates. A corrective parameter dependent on the characteristics of the strain gauge used is introduced by testing machines set up for isotropic materials. Theoretical results for a variety of strain gauges are compared with those obtained by a finite element method and with experimental results obtained on laminates reinforced with glass.

Vidouse, F.↗

NASA NTRS2018

An Efficient Inverse Finite Element Method for Shape and Stress Sensing of Laminated Composite and Sandwich Plates and Shells

The inverse Finite Element Method (iFEM) is a revolutionary methodology for real-time reconstruction of full-field structural displacements and stresses in structures that are instrumented with strain sensors. This inverse problem is commonly referred to as shape and stress sensing, which is well-recognized as an enabling technology for structural health monitoring systems. In this study, an improved iFEM formulation is proposed for shape and stress sensing of laminated composite and sandwich plates and shells. The formulation includes the kinematics of a shear deformation plate theory known as Refined Zigzag Theory (RZT) as its baseline. The present iFEM formulation is based upon the minimization of a weighted-least-squares functional that uses the complete set of section strains of RZT. The improved iFEM methodology is applicable for shape and stress sensing of thin and moderately thick plate and shell structures involving a relatively small number of strain gauges. The main advantage of the current formulation is that highly accurate through-the-thickness distributions of displacements, strains, and stresses are attainable using an element based on simple C0-continuous displacement interpolation functions. A three-node inverseshell element, named i3-RZT, is developed. Two example problems are examined in detail: (1) a simply supported rectangular laminated composite plate and (2) a wedge structure with a hole near one of the clamped ends. For both problems, the experimental strain data are generated numerically by the direct finite element analysis using high-fidelity discretizations. These strains are then regarded as the experimental strains obtained from surface mounted strain gauges or embedded fiber Bragg grating (FBG) sensors. The numerical results demonstrate the superior capability and potential applicability of the i3- RZT/iFEM methodology for performing accurate shape and stress sensing of complex composite structures.

Kefal, Adnan↗

NASA NTRS1990

An Ultrasonic Study on Anelasticity in Metals

A new ultrasonic approach for monitoring the anelastic behavior of metals and alloys was presented. The approach poses some problems related to separating the temperature dependence of the anelastic phenomena from the natural wave velocity s susceptibility to temperature changes. However, these effects can be distinguished and separated without much difficulty. Due to its high sensitivity to microstructural changes, the new technique will be quite valuable when used in conjunction with strain gauges for studying anelastic behavior. The two techniques should complement each other quite well. In the future, tests using both the P2L2 and strain gauges to more thoroughly monitor the samples will be conducted. Further work will be done to fully characterize the temperature sensitivity of the velocity and provide a more solid foundation for separating its effects.

Namkug, M.↗

NASA NTRS1987

Hand-Strength Meter

Special grip-strength meter designed for accurate, reproducible measurement of hand rehabilitation. Four strain gauges connected in Wheatstone bridge to measure deflection caused by gripping hand. Compressive force exerted by hand transmitted to measuring beams. Beams therefore deflected or strained, and mechanical strain sensed by strain gauges and converted into electrical signal. After amplification and conditioning, signal displayed on LED as measure of gripping strength of hand.

Tcheng, Ping↗

NASA NTRS2003

Advanced Packaging Technology Used in Fabricating a High-Temperature Silicon Carbide Pressure Sensor

The development of new aircraft engines requires the measurement of pressures in hot areas such as the combustor and the final stages of the compressor. The needs of the aircraft engine industry are not fully met by commercially available high-temperature pressure sensors, which are fabricated using silicon. Kulite Semiconductor Products and the NASA Glenn Research Center have been working together to develop silicon carbide (SiC) pressure sensors for use at high temperatures. At temperatures above 850 F, silicon begins to lose its nearly ideal elastic properties, so the output of a silicon pressure sensor will drift. SiC, however, maintains its nearly ideal mechanical properties to extremely high temperatures. Given a suitable sensor material, a key to the development of a practical high-temperature pressure sensor is the package. A SiC pressure sensor capable of operating at 930 F was fabricated using a newly developed package. The durability of this sensor was demonstrated in an on-engine test. The SiC pressure sensor uses a SiC diaphragm, which is fabricated using deep reactive ion etching. SiC strain gauges on the surface of the diaphragm sense the pressure difference across the diaphragm. Conventionally, the SiC chip is mounted to the package with the strain gauges outward, which exposes the sensitive metal contacts on the chip to the hostile measurement environment. In the new Kulite leadless package, the SiC chip is flipped over so that the metal contacts are protected from oxidation by a hermetic seal around the perimeter of the chip. In the leadless package, a conductive glass provides the electrical connection between the pins of the package and the chip, which eliminates the fragile gold wires used previously. The durability of the leadless SiC pressure sensor was demonstrated when two 930 F sensors were tested in the combustor of a Pratt & Whitney PW4000 series engine. Since the gas temperatures in these locations reach 1200 to 1300 F, the sensors were installed in water-cooled jackets, as shown. This was a severe test because the pressure-sensing chips were exposed to the hot combustion gases. Prior to the installation of the SiC pressure sensors, two high-temperature silicon sensors, installed in the same locations, did not survive a single engine run. The durability of the leadless SiC pressure sensor was demonstrated when both SiC sensors operated properly throughout the two runs that were conducted.

Beheim, Glenn M.↗

NASA NTRS1994

Instrumented Bolts Would Measure Shear Forces In Joints

Bolts instrumented with strain gauges used to measure shear forces. Bolts installed in multiple-bolt lap joints to obtain data on distribution of stresses and deformations in and around joints. Strain gauges indicate share of applied load borne by each individual bolt. In original application, bolted panels made of advanced refractory composite materials designed to withstand use at temperatures up to 4,000 degrees F. Also applicable to other joint materials and measurement of shear loads in other connections such as, shear loads on shafts in pulleys or gears.

Sawyer, James Wayne↗

NASA NTRS1995

Instrumented Bolt Measures Load In Two Ways

Bolt instrumented to allow both ultrasonic and strain-gauge measurements of tensile load in bolt during installation and use of bolt in structure. Bolt head design allows interface for ultrasonic transducer installed, while shallow chamfered circumferential groove on bolt shank contains four strain gauges at equal angular intervals wired as a full-bridge transducer.

Smith, D. E.↗

NASA NTRS1973

Strain gage installation on the YF-12 aircraft.

A flight-loads measurement program on the YF-12 aircraft required the mounting of 101 strain-gauge bridges in the fuselage, fuel tanks, control surfaces, and three stations on the left wing. The sensors were to be installed primarily on titanium and were required to operate between -70 and +600 F. Strain gauges with modified Karma filaments and backings of glass-fiber reinforced epoxy resin matrices were selected and were installed with an epoxy adhesive. Attention is given to the calibration, mounting, and performance of the sensors in flight-load measurements.

Wilson, E. J.↗

NASA NTRS2005

Autobalancing and FDIR for a space-based centrifuge prototype

This report summarizes centrifuge-related work performed at the Smart Systems Research Laboratory at NASA Ames Research Center's Computational Sciences Division from 1995 through 2003. The goal is to develop an automated system that will sense an imbalance (both static and dynamic3) in a centrifuge and issue control commands to drive counterweights to eliminate the effects of the imbalance. This autobalancing development began when the ISS centrifuge design was not yet finalized, and was designed to work with the SSRL Centrifuge laboratory prototype, constructed in 1993-1995. Significant differences between that prototype and the current International Space Station (ISS) Centrifuge design are that: the spin axis for the SSRL Centrifuge prototype can translate freely in x and y, but not wobble, whereas the ISS centrifuge spin axis has 3 translational and two rotational degrees of freedom, supported by a vibration 34. The imbalance sensors are strained gauges both in the rotor and the stator, measuring the imbalance forces, whereas the ISS centrifuge uses eddy current displacement sensors to measure the displacements resulting from imbalance. High fidelity autobalancing and FDIR systems (for both counterweights and strain gauges) are developed and tested in MATLAB simulation, for the SSRL Centrifuge configuration. Hardware implementation of the autobalancing technology was begun in 1996, but was terminated due to lack of funding. The project lay dormant until 2001-2002 when the FDIR capability was added.

Wilson, Edward↗

NASA NTRS1997

Advances in Thin Film Sensor Technologies for Engine Applications

Advanced thin film sensor techniques that can provide accurate surface strain and temperature measurements are being developed at NASA Lewis Research Center. These sensors are needed to provide minimally intrusive characterization of advanced materials (such as ceramics and composites) and structures (such as components for Space Shuttle Main Engine, High Speed Civil Transport, Advanced Subsonic Transports and General Aviation Aircraft) in hostile, high-temperature environments and for validation of design codes. This paper presents two advanced thin film sensor technologies: strain gauges and thermocouples. These sensors are sputter deposited directly onto the test articles and are only a few micrometers thick; the surface of the test article is not structurally altered and there is minimal disturbance of the gas flow over the surface. The strain gauges are palladium-13% chromium based and the thermocouples are platinum-13% rhodium vs. platinum. The fabrication techniques of these thin film sensors in a class 1000 cleanroom at the NASA Lewis Research Center are described. Their demonstration on a variety of engine materials, including superalloys, ceramics and advanced ceramic matrix composites, in several hostile, high-temperature test environments are discussed.

Lei, Jih-Fen↗

NASA NTRS2003

Investigation of Carbon-Polymer Structures with Embedded Fiber-Optic Bragg Gratings

Several Bragg-grating sensors fabricated within the same optical fiber are buried within multiple-ply carbon-epoxy planar and cylindrical structures. Effect of different orientation of fiber-sensors with respect to carbon fibers in the composite structure is investigated. This is done for both fabric and uni-tape material samples. Response of planar structures to axial and transverse strain up to 1 millistrain is investigated with distributed Bragg-grating sensors. Material properties like Young's Modulus and Poisson ratio is measured. A comparison is made between response measured by sensors in different ply-layers and those bonded on the surface. The results from buried fiber- sensors do not completely agree with surface bonded conventional strain gauges. A plausible explanation is given for observed differences. The planar structures are subjected to impacts with energies up to 10 ft-lb. Effect of this impact on the material stiffness is also investigated with buried fiber-optic Bragg sensors. The strain response of such optical sensors is also measured for cylindrical carbon-epoxy composite structures. The sensors are buried within the walls of the cylinder as well as surface bonded in both the axial as well as hoop directions. The response of these fiber-optic sensors is investigated by pressurizing the cylinder up to its burst pressure of around 1500 psi. This is done at both room temperature as well as cryogenic temperatures. The recorded response is compared with that from a conventional strain gauge.

Grant, Joseph↗

NASA NTRS2019

Estimating Inducer Blade Damping in Water with On-Blade Strain Measurements

This paper describes the testing, methodology, and results for estimating critical damping ratios of inducer blade structural natural frequencies. A sub-scale inducer water flow test was performed with on-blade strain gauge measurements. Data were acquired in quiescent air and water, and also at several shaft speeds and operating conditions. Two methods were used to provide active excitation to the blades. The first was to impart a mechanical impulse to the inducer shaft and observe the strain gauge response. The second was to install a stator plate upstream of the inducer to create a non-uniform but regular pressure field at the inducer inlet. There are challenges with using either approach, but damping information was extracted using both methods. Results showed that the critical damping ratio for a given blade mode increased from air to quiescent water, and also increased when the inducer was spinning.

Mulder, Andrew↗

NASA NTRS2004

Study and Analyses on the Structural Performance of a Balance

Strain-gauge balances for use in wind tunnels have been designed at Langley Research Center (LaRC) since its inception. Currently Langley has more than 300 balances available for its researchers. A force balance is inherently a critically stressed component due to the requirements of measurement sensitivity. The strain-gauge balances have been used in Langley s wind tunnels for a wide variety of aerodynamic tests, and the designs encompass a large array of sizes, loads, and environmental effects. There are six degrees of freedom that a balance has to measure. The balance s task to measure these six degrees of freedom has introduced challenging work in transducer development technology areas. As the emphasis increases on improving aerodynamic performance of all types of aircraft and spacecraft, the demand for improved balances is at the forefront. Force balance stress analysis and acceptance criteria are under review due to LaRC wind tunnel operational safety requirements. This paper presents some of the analyses and research done at LaRC that influence structural integrity of the balances. The analyses are helpful in understanding the overall behavior of existing balances and can be used in the design of new balances to enhance performance. Initially, a maximum load combination was used for a linear structural analysis. When nonlinear effects were encountered, the analysis was extended to include nonlinearities using MSC.Nastran . Because most of the balances are designed using Pro/Mechanica , it is desirable and efficient to use Pro/Mechanica for stress analysis. However, Pro/Mechanica is limited to linear analysis. Both Pro/Mechanica and MSC.Nastran are used for analyses in the present work. The structural integrity of balances and the possibility of modifying existing balances to enhance structural integrity are investigated.

Karkehabadi, R.↗