Effects of some processing variables on dimensional stability.
Precision device dimensional stability and relaxation of residual stresses introduced during processing, noting design, material selection and material processing
Imgram, A. G.↗
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Analysis of multilayered fiber composites
Multilevel analysis computer program is useful in fiber matrix composites diagnosis, in structural syntheses of multilayered thornel/epoxy composite plates, in buckling studies of simply supported multilayered fiber composite plates, and in computing lamination residual stresses in angle ply composites.
Chamis, C. C.↗
Designing for impact resistance with unidirectional fiber composites
Impact resistant unidirectional fiber composite design based on micro and macromechanics, Izod impact tests, and residual stress and structural analyses
Chamis, C. C.↗
Investigation of flaw geometry and loading effects on plane strain fracture in metallic structures
The effects on fracture and flaw growth of weld-induced residual stresses, combined bending and tension stresses, and stress fields adjacent to circular holes in 2219-T87 aluminum and 5AI-2.5Sn(ELI) titanium alloys were evaluated. Static fracture tests were conducted in liquid nitrogen; fatigue tests were performed in room air, liquid nitrogen, and liquid hydrogen. Evaluation of results was based on linear elastic fracture mechanics concepts and was directed to improving existing methods of estimating minimum fracture strength and fatigue lives for pressurized structure in spacecraft and booster systems. Effects of specimen design in plane-strain fracture toughness testing were investigated. Four different specimen types were tested in room air, liquid nitrogen and liquid hydrogen environments using the aluminum and titanium alloys. Interferometry and holograph were used to measure crack-opening displacements in surface-flawed plexiglass test specimens. Comparisons were made between stress intensities calculated using displacement measurements, and approximate analytical solutions.
Hall, L. R.↗
Integration of NASA-sponsored studies on aluminum welding
The results are presented of numerous studies relating to aluminum alloy welding. The subjects covered include: (1) effects of porosity on weld joint performance, (2) sources of porosity, (3) weld thermal effects, (4) residual stresses and distortion, and (5) manufacturing process system control.
Masubuchi, K.↗
Investigation of forming curved ablative panels from flat panels for space shuttle
The purpose of this study was to determine the feasibility of reforming flat ablative panels to a curved configuration. The study indicated that if the panels could be shaped to a radius of 2.54 m (100 in.) then 88.7% of the surface area of the orbiter could be covered, and that if they could be shaped to a radius of 3.81 m (150 in.) then 77.2% of the surface could be covered. Two basic approaches were followed to determine the best method for forming the flat panels to a curved shape. The first was to determine if partially cured panels could be formed, allowing the forming heat cycle to complete the curing of the ablator. The second method was to form fully cured flat panels into the desired curvature through a secondary heat cycle. Measurements made on the panels during storage indicated that they continued to straighten out over time. This was attributed to residual stresses locked into the panels that had not been fully relaxed by the heat cycle.
Chandler, H. H.↗
The line spring model for surface flaws.
A model is discussed for the analysis of long part-through surface cracks in the walls of plate or shell structures. Such problems are formulated within the context of two dimensional plate and shell theory with the part-cracked section represented as a line-spring in the middle surface. The spring allows relative separations and rotations of the middle surface, and constitutive laws relating these discontinuities to the prevailing force and moment per unit length at any point are taken from the plane strain solution for a strip in combined tension and bending, which contains an edge crack of a corresponding depth. Prior work is reviewed and further line spring constitutive laws are discussed as appropriate to elastic analysis with thermal or residual stresses and to elastic-plastic analysis, with yielding in the ligament between the crack front and far wall in the latter case.
Rice, J. R.↗
Ultrasonics
Ultrasonic testing is discussed as a primary means of nondestructive evaluation of subsurface flaws. The advantages and disadvantages are listed. The elementary principles, basic components of test units, scan modes, resonance testing, detection of fatigue cracks, monitoring fatigue crack growth, and determination of residual stress are discussed.
Leonard, B. E.↗
Dissimilar metals joint evaluation
Dissimilar metals tubular joints between 2219-T851 aluminum alloy and 304L stainless steel were fabricated and tested to evaluate bonding processes. Joints were fabricated by four processes: (1) inertia (friction) weldings, where the metals are spun and forced together to create the weld; (2) explosive welding, where the metals are impacted together at high velocity; (3) co-extrusion, where the metals are extruded in contact at high temperature to promote diffusion; and (4) swaging, where residual stresses in the metals after a stretching operation maintain forced contact in mutual shear areas. Fifteen joints of each type were prepared and evaluated in a 6.35 cm (2.50 in.) O.D. size, with 0.32 cm (0.13 in.) wall thickness, and 7.6 cm (3.0 in) total length. The joints were tested to evaluate their ability to withstand pressure cycle, thermal cycle, galvanic corrosion and burst tests. Leakage tests and other non-destructive test techniques were used to evaluate the behavior of the joints, and the microstructure of the bond areas was analyzed.
Wakefield, M. E.↗
A computational procedure to analyze metal matrix laminates with nonlinear lamination residual strains
An approximate computational procedure is described for the analysis of angleplied laminates with residual nonlinear strains. The procedure consists of a combination of linear composite mechanics and incremental linear laminate theory. The procedure accounts for initial nonlinear strains, unloading, and in-situ matrix orthotropic nonlinear behavior. The results obtained in applying the procedure to boron/aluminum angleplied laminates show that this is a convenient means to accurately predict the initial tangent properties of angleplied laminates in which the matrix has been strained nonlinearly by the lamination residual stresses. The procedure predicted initial tangent properties results which were in good agreement with measured data obtained from boron/aluminum angleplied laminates.
Chamis, C. C.↗
Development of a gas pressure bonded four-pole alternator rotor
Methods were developed for fabrication of a solid four pole alternator rotor by hot isostatic pressure welding. The rotor blanks welded in this program had complex geometrical mating interfaces and were of considerable bulk, being approximately 3-1/2 inches (0.089 meters) in diameter and 14 inches (0.356 meters) long. Magnetic end pieces were machined from AlSl 4340 steel, while the non-magnetic central section was of Inconel 718. Excellent welds were produced which were shown to be responsive to post weld heat treatments which substantially improved joint strength. Prior to welding the rotors, test specimens of complex geometry were welded to demonstrate that complex surfaces with intentional mechanical misfit could be readily joined using HIP welding. This preliminary work demonstrated not only that interface compliance is achieved during welding but that welding pressure is developed in these thick sections sufficient to produce sound joints. Integral weld-heat treatment cycles were developed that permitted the attainment of magnetic properties while minimizing residual stress associated with the allotropic transformation of 4340 steel.
Lessmann, G. G.↗
Diffusion bonding and its application to manufacturing
In its simplest form diffusion bonding is accomplished by placing clean metal surfaces together under a sufficient load and heating. The natural interatomic attractive force between atoms transforms the interface into a natural grain boundary. Therefore, in principle, the properties of the bond area are identical to those of the parent metal. Other advantages of diffusion bonding over conventional methods of bonding include freedom from residual stresses, excessive deformation, foreign metals, or changed crystal structures. Stainless steels, nickel-base superalloys, and aluminum alloys have all been successfully joined. Complex hardware, including integrated flueric devices, jet engine servovalves, and porous woven structures have been fabricated. The processing involved is discussed, along with such theoretical considerations as the role of metal surfaces, the formation of metal contact junctions, and the mechanisms of material transport in diffusion bonding.
Spurgeon, W. M.↗
Improved ultrasonic standard reference blocks
A program to improve the quality, reproducibility and reliability of nondestructive testing through the development of improved ASTM-type ultrasonic reference standards is described. Reference blocks of aluminum, steel, and titanium alloys were considered. Equipment representing the state-of-the-art in laboratory and field ultrasonic equipment was obtained and evaluated. Some RF and spectral data on ten sets of ultrasonic reference blocks were taken as part of a task to quantify the variability in response from nominally identical blocks. Techniques for residual stress, preferred orientation, and microstructural measurements were refined and are applied to a reference block rejected by the manufacturer during fabrication in order to evaluate the effect of metallurgical condition on block response.
Eitzen, D. G.↗
A computational procedure to analyze metal matrix laminates with nonlinear lamination residual strains
An approximate computational procedure is described for the analysis of angleplied laminates with residual nonlinear strains. The procedure consists of a combination of linear composite mechanics and incremental linear laminate theory. The procedure accounts for initial nonlinear strains, unloading, and in-situ matrix orthrotropic nonlinear behavior. The results obtained in applying the procedure to boron/aluminum angleplied laminates show that this is a convenient means to accurately predict the initial tangent properties of angleplied laminates in which the matrix has been strained nonlinearly by the lamination residual stresses. The procedure predicted initial tangent properties results which were in good agreement with measured data obtained from boron/aluminum angleplied laminates.
Chamis, C. C.↗
Changes in boron fiber strength due to surface removal by chemical etching
The effects of chemical etching on the tensile strength of commercial boron/tungsten fibers were investigated. Fibers with as-received diameters of 203, 143, and 100 micrometers were etched to diameters as small as 43 micrometers. The etching generally resulted in increasing fiber tensile strength with decreasing fiber diameter. And for the 203 micrometer fibers there was an accompanying significant decrease in the coefficient of variation of the tensile strength for diameters down to 89 micrometers. Heat treating these fibers above 1,173 K in a vacuum caused a marked decrease in the average tensile strength of at least 80 percent. But after the fibers were etched, their strengths exceeded the as-received strengths. The tensile strength behavior is explained in terms of etching effects on surface flaws and the residual stress pattern of the as-received fibers.
Smith, R. J.↗
Improved ultrasonic standard reference blocks
A program to improve the quality, reproducibility and reliability of nondestructive testing through the development of improved ASTM-type ultrasonic reference standards is described. Reference blocks of aluminum, steel, and titanium alloys are to be considered. Equipment representing the state-of-the-art in laboratory and field ultrasonic equipment was obtained and evaluated. RF and spectral data on ten sets of ultrasonic reference blocks have been taken as part of a task to quantify the variability in response from nominally identical blocks. Techniques for residual stress, preferred orientation, and micro-structural measurements were refined and are applied to a reference block rejected by the manufacturer during fabrication in order to evaluate the effect of metallurgical condition on block response. New fabrication techniques for reference blocks are discussed and ASTM activities are summarized.
Eitzen, D. G.↗
Laser-zone growth in a Ribbon-To-Ribbon (RTR) process silicon sheet growth development for the large area silicon sheet task of the low cost silicon solar array project
The Ribbon-to-Ribbon (RTR) approach to silicon ribbon growth was investigated. An existing RTR apparatus, RTR#1, was upgraded to allow for 5 cm wide ribbon growth with a finite stroke length of at least 15 cm. A second RTR apparatus, RTR#2, was designed, built, and operated which utilizes continuous feed mechanisms and allows continuous growth of 7.5 cm wide ribbons. RTR#2 includes development and utilization of advanced beam scanning (or shaping), high power lasers, and thermal profile modification elements to attain maximum growth velocities (with a design goal of 18 cm/min). Materials studies, process development, and thermal analyses are also described. Residual stresses and dislocation densities were minimized through theoretical and experimental efforts towards optimization of thermal profiles. Growth runs were performed on RTR#2 and solar cells were fabricated which demonstrated efficiencies greater than 10%.
Gurtler, R. W.↗
Influences of chemical and thermal environments on delay in a Ti-6Al-4V alloy
Experiments were conducted within the framework of linear fracture mechanics to study the effects of chemical and thermal environments on crack-growth retardation (delay) in mill-annealed Ti-6Al-4V alloy under elemental load spectra. Attention is focused on the influence of hold time at high load on delay in a 3.5 percent NaCl solution at room temperature. It is shown that delay is strongly affected by hold time at high load, where delay is longest if the high-load excursion occurs at high temperature and the subsequent fatigue is at room temperature, and shortest if the temperature profile is reversed. The results suggest that residual stresses ahead of the advancing crack play an important role in delay. The significance of combined load and environment (chemical and thermal) effects in terms of modeling and life prediction procedures is discussed.
Shih, T. T.↗