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NASA NTRS1987

Advances in 3-D Inelastic Analysis Methods for hot section components

3-D Inelastic Analysis Methods are described. These methods consist of a series of new computer codes embodying a progression of mathematical models (mechanics of materials, specialty finite element, boundary element) for streamlined analysis of: (1) combustor liners, (2) turbine blades, and (3) turbine vanes. These models address the effects of high temperatures and thermal/mechanical loadings on the local (stress/strain) and global (dynamics, buckling) structural behavior of the three selected components. Three computer codes, referred to as MOMM (Mechanics of Materials Model), MHOST (MARC-Hot Section Technology), and BEST (Boundary Element Stress Technology), have been developed and are briefly described in this paper.

Chamis, Christos C.↗

NASA NTRS1985

Creep fatigue life prediction for engine hot section materials (isotropic): Third year progress review

This program is designed to investigate fundamental damage processes, identify modeling strategies, and develop practical models which can be used to guide the early design and development of new engines and to increase the durability of existing engines. A review is given of the base program, completed in 1984, which included the comparison and evaluation of several popular high-temperature life prediction approaches as applied to continuously cycled isothermal specimen tests. The option program, of which one year is completed, is designed to develop models which can account for complex cycles and loadings, such as thermomechanical cycling, cumulative damage, multiaxial stress/strain rates, and environmental effects.

Nelson, Richard S.↗

NASA NTRS1988

Fatigue damage mapping

Observations of fatigue crack nucleation and early growth are presented. The state of stress/strain was shown to play a significant role in this process. Early growth occurs on planes experiencing the largest range of shear strain (Mode 2) or normal strain (Mode 1) depending on the stress state, strain amplitude, and microstructure. These observations were summarized in a fatigue map for each material. These maps provide regions where one fatigue failure mode dominates the behavior. Each failure mechanism results in a different failure mode. Once the expected failure mode is identified, bulk deformation models based on the cyclic stresses and strains can be used to obtain reliable estimates of fatigue lives for complex loading situations.

Socie, Darrell↗

NASA NTRS1987

Image transfer in photorefractive GaAs

Image transfer from one beam to the other using counterpropagation beam coupling in GaAs was demonstrated. Good image quality was achieved. The results also reveal that local birefringence due to the residual stress/strain field in the crystal can degrade the image quality.

Cheng, Li-Jen↗

NASA NTRS1989

Advanced methods for 3-D inelastic structural analysis for hot engine structures

Three-dimensional Inelastic Analysis Methods are described. These methods were incorporated into a series of new computer codes embodying a progression of mathematical models (mechanics of materials, specialty finite element, boundary element) for streamlined analysis of hot engine structures such as: (1) combustor liners, (2) turbine blades, and (3) turbine vanes. These models address the effects of high temperatures and thermal/mechanical loadings on the local (stress/strain) and global (displacements, frequencies, amplitudes, buckling) structural behavior of the three respective components. The methods and the three computer codes, referred to as MOMM (Mechanics Of Materials Model), MHOST (MARC-Hot Section Technology), and BEST3D (Boundary Element Stress Technology), have been developed and are briefly described.

Chamis, C. C.↗

NASA NTRS1989

Space Shuttle Main Engine structural analysis and data reduction/evaluation. Volume 1: Aft Skirt analysis

Using the ANSYS finite element program, a global model of the aft skirt and a detailed nonlinear model of the failure region was made. The analysis confirmed the area of failure in both STA-2B and STA-3 tests as the forging heat affected zone (HAZ) at the aft ring centerline. The highest hoop strain in the HAZ occurs in this area. However, the analysis does not predict failure as defined by ultimate elongation of the material equal to 3.5 percent total strain. The analysis correlates well with the strain gage data from both the Wyle influence test of the original design aft sjirt and the STA-3 test of the redesigned aft skirt. it is suggested that the sensitivity of the failure area material strength and stress/strain state to material properties and therefore to small manufacturing or processing variables is the most likely cause of failure below the expected material ultimate properties.

Berry, David M.↗

NASA NTRS1989

Neutron and high speed photogrammetric arcjet diagnosis

Two methods for real time internal diagnostics of arcjet engines are described. One method uses cold, thermal, or epithermal neutrons. Cold neutrons are used to detect the presence and location of hydrogenous propellants. Thermal neutrons are used to delineate the edge contours of anode and cathode surfaces and to measure stress/strain. Epithermal neutrons are used to measure temperatures on arcjet surfaces, bulk material temperatures, and point temperatures in bulk materials. It is found that this method, with an exposure time of 10 min, produces at temperature accuracy for W or Re of + or - 2.5 C. The other method uses visible-light high-speed photogrammetry to obtain images of the transient behavior of the arc during start-up and to relate this behavior to electrial supply characteristics such as voltage, current, and ripple.

Stewart, P. A. E.↗

NASA NTRS1990

A real time neural net estimator of fatigue life

A neural net architecture is proposed to estimate, in real-time, the fatigue life of mechanical components, as part of the Intelligent Control System for Reusable Rocket Engines. Arbitrary component loading values were used as input to train a two hidden-layer feedforward neural net to estimate component fatigue damage. The ability of the net to learn, based on a local strain approach, the mapping between load sequence and fatigue damage has been demonstrated for a uniaxial specimen. Because of its demonstrated performance, the neural computation may be extended to complex cases where the loads are biaxial or triaxial, and the geometry of the component is complex (e.g., turbopump blades). The generality of the approach is such that load/damage mappings can be directly extracted from experimental data without requiring any knowledge of the stress/strain profile of the component. In addition, the parallel network architecture allows real-time life calculations even for high frequency vibrations. Owing to its distributed nature, the neural implementation will be robust and reliable, enabling its use in hostile environments such as rocket engines. This neural net estimator of fatigue life is seen as the enabling technology to achieve component life prognosis, and therefore would be an important part of life extending control for reusable rocket engines.

Troudet, T.↗

NASA NTRS1990

METCAN verification status

The status of the verification (comparisons of predictions with experimental data) of the METCAN (METal-matrix Composite ANalyzer) code at high temperature is summarized. Verification includes select available room temperature of W/Cu composites for different fiber volume ratios. It also includes high temperature properties for thermal expansion, moduli, strength and stress/strain behavior for SiC/Ti composites. Furthermore it includes limited cases for thermal fatigue strength degradation. The verification results summarized herein indicate that METCAN simulates complex high temperature metal matrix composite bahavior with reasonable accuracy and that it can be used with confidence to identify in-situ nonlinear behavior that influences composite properties.

Chamis, Christos C.↗

NASA NTRS1990

Shape-memory properties in Ni-Ti sputter-deposited film

A Ni-Ti alloy, generically called nitinol, was prepared from sputtering targets of two different compositions on glass substrates using a dc magnetron source. The as-deposited films were amorphous in structure and did not exhibit a shape memory. The amorphous films were crystallized with a suitable annealing process, and the transformation properties were measured using differential scanning calorimetry. The annealed films demonstrated a strong shape-memory effect. Stress/strain measurements and physical manipulation were used to evaluate the shape recovery. These tests demonstrated sustained tensile stresses of up to 480 MPa in the high-temperature phase, and a characteristic plastic deformation in the low-temperature phase.

Busch, J. D.↗

NASA NTRS1992

Scaling effects in angle-ply laminates

The effect of specimen size upon the response and strength of +/- 45 degree angle-ply laminates was investigated for two graphite fiber reinforced plastic systems and several stacking sequences. The first material system was a brittle epoxy based system, AS4 fibers in 3502 epoxy, and the second was a tough thermoplastic based system, AS4 fibers in PEEK matrix. For the epoxy based system, two generic +/- 45 degree lay-ups were studied: (+45 degrees sub n/-45 degrees sub n) sub 2S (blocked plies), and (+45 degrees/-45 degrees) sub 2nS, for n=1 and 2. The in-plane dimensions of the specimens were varied such that the width/length relationship was 12.7 x n/127 x n mm, for m=1, 2, 3, or 4. It is shown that the stress/strain response and the ultimate strength of these angle-ply laminates depends on the laminate thickness and the type of generic lay-up used. Furthermore, it is shown that first ply failure occurs in the surface plies as a result of normal rather than shear stresses. The implications of the experimental findings upon the validity of the +/- 45 degree tensile test which is used to determine the in-plane shear response of unidirectional composites are discussed.

Kellas, Sotiris↗

NASA NTRS1992

Algebraic surface design and finite element meshes

Some of the techniques are summarized which are used in constructing C sup 0 and C sup 1 continuous meshes of low degree, implicitly defined, algebraic surface patches in three dimensional space. These meshes of low degree algebraic surface patches are used to construct accurate computer models of physical objects. These meshes are also used in the finite element simulation of physical phenomena (e.g., heat dissipation, stress/strain distributions, fluid flow characteristics) required in the computer prototyping of both the manufacturability and functionality of the geometric design.

Bajaj, Chandrajit L.↗

NASA NTRS1990

A real time neural net estimator of fatigue life

A neural network architecture is proposed to estimate, in real-time, the fatigue life of mechanical components, as part of the intelligent Control System for Reusable Rocket Engines. Arbitrary component loading values were used as input to train a two hidden-layer feedforward neural net to estimate component fatigue damage. The ability of the net to learn, based on a local strain approach, the mapping between load sequence and fatigue damage has been demonstrated for a uniaxial specimen. Because of its demonstrated performance, the neural computation may be extended to complex cases where the loads are biaxial or triaxial, and the geometry of the component is complex (e.g., turbopumps blades). The generality of the approach is such that load/damage mappings can be directly extracted from experimental data without requiring any knowledge of the stress/strain profile of the component. In addition, the parallel network architecture allows real-time life calculations even for high-frequency vibrations. Owing to its distributed nature, the neural implementation will be robust and reliable, enabling its use in hostile environments such as rocket engines.

Troudet, T.↗

NASA NTRS1991

An evaluation of the +/-45 deg tensile test for the determination of the in-plane shear strength of composite materials

The applicability of the +/-45 deg tensile test for the determination of the in-plane shear strength of advanced composite laminates is studied. The assumptions used for the development of the shear strength formulas were examined, and factors such as the specimen geometry and stacking sequence were assessed experimentally. It was found that the strength of symmetric and balanced +/-45 deg laminates depends primarily upon the specimen thickness rather than the specimen width. These findings have important implications for the +/-45 deg tensile test which is recommended by several organizations for the determination of the in-plane shear stress/strain response and the shear strength of continuous fiber reinforced composites. Modifications to the recommended practices for specimen selection and shear strength determination are suggested.

Kellas, S.↗

NASA NTRS1992

Experimental characterization of nonlinear, rate-dependent behavior in advanced polymer matrix composites

In order to support materials selection for the next-generation supersonic civilian-passenger transport aircraft, a study has been undertaken to evaluate the material stress/strain relationships needed to describe advanced polymer matrix composites under conditions of high load and elevated temperature. As part of this effort, this paper describes the materials testing which was performed to investigate the viscoplastic behavior of graphite/thermoplastic and graphite/bismaleimide composites. Test procedures, results and data-reduction schemes which were developed for generating material constants for tension and compression loading, over a range of useful temperatures, are explained.

Gates, Thomas S.↗

NASA NTRS1992

The 1992 NASA Langley Measurement Technology Conference: Measurement Technology for Aerospace Applications in High-Temperature Environments

An intensive 2-day conference to discuss the current status of measurement technology in the areas of temperature/heat flux, stress/strain, pressure, and flowfield diagnostics for high temperature aerospace applications was held at Langley Research Center, Hampton, Virginia, on April 22 and 23, 1993. Complete texts of the papers presented at the Conference are included in these proceedings.

Singh, Jag J.↗

NASA NTRS1993

The Design of Mechanically Compatible Fasteners for Human Mandible Reconstruction

Mechanically compatible fasteners for use with thin or weakened bone sections in the human mandible are being developed to help reduce large strain discontinuities across the bone/implant interface. Materials being considered for these fasteners are a polyetherertherketone (PEEK) resin with continuous quartz or carbon fiber for the screw. The screws were designed to have a shear strength equivalent to that of compact/trabecular bone and to be used with a conventional nut, nut plate, or an expandable shank/blind nut made of a ceramic filled polymer. Physical and finite element models of the mandible were developed in order to help select the best material fastener design. The models replicate the softer inner core of trabecular bone and the hard outer shell of compact bone. The inner core of the physical model consisted of an expanding foam and the hard outer shell consisted of ceramic particles in an epoxy matrix. This model has some of the cutting and drilling attributes of bone and may be appropriate as an educational tool for surgeons and medical students. The finite element model was exercised to establish boundary conditions consistent with the stress profiles associated with mandible bite forces and muscle loads. Work is continuing to compare stress/strain profiles of a reconstructed mandible with the results from the finite element model. When optimized, these design and fastening techniques may be applicable, not only to other skeletal structures, but to any composite structure.

Roberts, Jack C.↗

NASA NTRS1993

Probabilistic assessment of composite structures

A methodology and attendant computer code were developed and are used to computationally simulate the uncertain behavior of composite structures. The uncertain behavior includes buckling loads, stress concentration factors, displacements, stress/strain, etc., which are the consequences of the inherent uncertainties (scatter) in the primitive (independent random) variables (constituent, ply, laminate, and structural) that describe the composite structures. The computer code is IPACS (Integrated Probabilistic Assessment of Composite Structures). IPACS can simulate both composite mechanics and composite structural behavior. Application to probabilistic composite mechanics is illustrated by its use to evaluate the uncertainties in the major Poisson's ratio and in laminate stiffness and strength. IPACS' application to probabilistic structural analysis is illustrated by its used to evaluate the uncertainties in the buckling of a composite plate, the stress concentration factor in a composite panel, and the vertical displacement and ply stress in a composite aircraft wing segment. IPACS' application to probabilistic design is illustrated by its use to assess the thin composite shell (pipe).

Chamis, C. C.↗