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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Microstructure and Mechanical Properties of Reaction-Formed Joints in Reaction Bonded Silicon Carbide Ceramics

A reaction-bonded silicon carbide (RB-SiC) ceramic material (Carborundum's Cerastar RB-SIC) has been joined using a reaction forming approach. Microstructure and mechanical properties of three types of reaction-formed joints (350 micron, 50-55 micron, and 20-25 micron thick) have been evaluated. Thick (approximately 350 micron) joints consist mainly of silicon with a small amount of silicon carbide. The flexural strength of thick joints is about 44 plus or minus 2 MPa, and fracture always occurs at the joints. The microscopic examination of fracture surfaces of specimens with thick joints tested at room temperature revealed the failure mode to be typically brittle. Thin joints (<50-55 micron) consist of silicon carbide and silicon phases. The room and high temperature flexural strengths of thin (<50-55 micron) reaction-formed joints have been found to be at least equal to that of the bulk Cerastar RB-SIC materials because the flexure bars fracture away from the joint regions. In this case, the fracture origins appear to be inhomogeneities inside the parent material. This was always found to be the case for thin joints tested at temperatures up to 1350C in air. This observation suggests that the strength of Cerastar RB-SIC material containing a thin joint is not limited by the joint strength but by the strength of the bulk (parent) materials.

Singh, M.↗
NASA NTRS1989

Effect of bond thickness on fracture and fatigue strength of adhesively bonded composite joints

An experimental investigation of composite to composite bonded joints was undertaken to study the effect of bond thickness on debond growth rate under cyclic loading and critical strain energy release rate under static loading. Double cantilever beam specimens of graphite/epoxy adherends bonded with EC 3445 were tested under mode I loading. A different behavior of fracture and fatigue strength was observed with variation of bondline thickness.

Mall, S.↗
NASA NTRS1944

Fatigue Strength and Related Characteristics of Aircraft Joints I : Comparison of Spot-Weld and Rivet Patterns in 24s-t Alclad and 75s-t Alclad

Report contains detailed results of a number of fatigue tests on spot-welded joints in aluminum alloys. The tests described include: (1) fatigue tests on spot-welded lap joints in sheets of unequal thickness of alclad 24s-t. These tests indicate that the fatigue strength of a spot-welded joint in sheets of two different gages is slightly higher than that of a similar joint in two sheets of the thinner gage but definitely lower than that of a similar joint in two sheets of the thicker gage. (2) Fatigue tests on spot-welded alclad 75s-t spot-welded lap-joint specimens of alclad 75s-t were not any stronger in fatigue than similar specimens of alclad 24s-t. (3) Fatigue tests on lap-joint specimens spot -welded after various surface preparations--these included ac welding wire-brushed surfaces, dc welding wire-brushed surfaces, and dc welding chemically cleaned surfaces. While the ac welds were strongest statically, the dc welds on wire-brushed surfaces were strongest in fatigue. Specimens prepared in this way were very nearly as strong as the best riveted specimens tested for comparison. (4) Fatigue tests on specimens spot-welded with varying voltage so as to include a wide range of static spot-weld strengths. The fatigue strengths were in the same order as the static strengths but showed less range. (author)

Russell, H W↗
NASA NTRS1980

Investigation of the fuel feed line failures on the Space Shuttle main engine

The Space Shuttle Main Engine (SSME) development program experienced two similar appearing fuel feed line failures during the shutdown portion of two engine tests. Failure investigations into each incident showed that a few cycles of high-amplitude transient strain occurring during the start and cutoff portions of each test could have either accumulated damage and led to a fatigue failure after 46 tests, or caused rupture in a low-strength weld joint. The cause of the high strain was traced to a period of unsteady flow separation during the start and cutoff of each test coincident with the oblique shock approaching the nozzle exit. Since elimination of the flow separation was impractical, the steps taken to allow engine development and flight preparations to continue were: (1) establish the safe operating life of the nozzle, (2) reinforce all low-strength welds, and (3) eliminate the use of thin-wall fuel feed lines. In parallel, the feed line was redesigned and fabrication was initiated on units to be incorporated into the development program.

Larson, E. W.↗
NASA NTRS2001

Friction Stir Welding Development at NASA, Marshall Space Flight Center

Friction stir welding (FSW) is a solid state process that pan be used to join materials without melting. The process was invented by The Welding Institute (TWI), Cambridge, England. Friction stir welding exhibits several advantages over fusion welding in that it produces welds with fewer defects and higher joint efficiency and is capable of joining alloys that are generally considered non-weldable with a fusion weld process. In 1994, NASA-Marshall began collaborating with TWI to transform FSW from a laboratory curiosity to a viable metal joining process suitable for manufacturing hardware. While teamed with TWI, NASA-Marshall began its own FSW research and development effort to investigate possible aerospace applications for the FSW process. The work involved nearly all aspects of FSW development, including process modeling, scale-up issues, applications to advanced materials and development of tooling to use FSW on components of the Space Shuttle with particular emphasis on aluminum tanks. The friction stir welding process involves spinning a pin-tool at an appropriate speed, plunging it into the base metal pieces to be joined, and then translating it along the joint of the work pieces. In aluminum alloys the rotating speed typically ranges from 200 to 400 revolutions per minute and the translation speed is approximately two to five inches per minute. The pin-tool is inserted at a small lead angle from the axis normal to the work piece and requires significant loading along the axis of the tool. An anvil or reaction structure is required behind the welded material to react the load along the axis of the pin tool. The process requires no external heat input, filler material, protective shielding gas or inert atmosphere typical of fusion weld processes. The FSW solid-state weld process has resulted in aluminum welds with significantly higher strengths, higher joint efficiencies and fewer defects than fusion welds used to join similar alloys.

McGill, Preston↗
NASA NTRS2000

Design, Fabrication, and Testing of Ceramic Joints for High Temperature SiC/SiC Composites

Various issues associated with the design and mechanical evaluation of joints of ceramic matrix composites are discussed. The specific case of an affordable, robust ceramic joining technology (ARCJoinT) to join silicon carbide (CG-Nicalon(sup TM)) fiber-reinforced-chemically vapor infiltrated (CVI) silicon carbide matrix composites is addressed. Experimental results are presented for the time and temperature dependence of the shear strength of these joints in air up to 1200 C. From compression testing of double-notched joint specimens with a notch separation of 4 mm, it was found that the apparent shear strength of the joints decreased from 92 MPa at room temperature to 71 MPa at 1200 C. From shear stress-rupture testing in air at 1200 C it was found that the shear strength of the joints decreased rapidly with time from an initial shear strength of 71 to 17.5 MPa after 14.3 hr. The implications of these results in relation to the expected long-term service life of these joints in applications at elevated temperatures are discussed.

Singh, Mrityunjay↗
NASA NTRS1985

Strength of Graphite/Metal Composite Lap Joints

Report presents results of tests on fastened lap joints between strips of graphite/aluminum and graphite/magnesium composites. Goal of test program was to establish practical load range and effect of such joint parameters as load direction relative to graphite fiber direction, edge distance, fastener diameters, and lateral spacing as function of net section efficiency.

Ellison, A.↗
NASA NTRS1991

Bonding Aramid Rope To Metal Fitting

Method for joining Kevlar (or equivalent) aramid rope to tubular corrosion-resistant steel end fitting increases strength of joint under tension to approximately three-fourths that of rope itself. End fitting contains internal thread, which provides good bonding surface. Small radial hole enables injection of adhesive into bore.

To, Dung T.↗
NASA NTRS1944

Fatigue Strength and Related Characteristics of Joints in 24s-t Alclad Sheet

Report includes tension fatigue test results on the following types of samples of 0.040-inch alclad 24s-t: (1) monoblock sheet samples as received and after a post-aging heat treatment, (2) "sheet efficiency" samples (two equally stressed sheets joined by a single transverse row of spot welds) both as received and after post-aging, (3) spot-welded lap-joint samples as received and after post-aging, and (4) roll-welded lap-joint samples. (author)

Russell, H W↗
NASA NTRS1940

New Equipment for Testing the Fatigue Strength of Riveted and Welded Joints

The mechanical and electrical construction of a new experimental instrument for fatigue testing riveted and welded joints is described. This experimental device has the advantage of being able to stress, even with comparatively low magnetic exciter force, structural components in alternate bending by resonance vibrations up to incipient fatigue failure.

Muller, W↗
NASA NTRS1993

A study of strength evaluations of EDNi/EDCu/NARloy-Z bonded joints

Dissimilar material interfaces can be found in many materials and structural bonds such as composite materials, welded parts, inclusion in matrix, bond between metallic and ceramic materials, and so forth. One of such structural bonds can be seen in the main combustion chamber (MCC) of the Space Shuttle Main Engine (SSME). In this study, from a practical sense, the primary concern is to understand the systems response of EDNi/EDCu/NARloy-Z bonded joints using stress values approximated by the finite element method to determine an influence of the variation of structural bond parameters on the bonded joints, and consequently main combustion chamber of the Space Shuttle Main Engine. The results presented in this study could be an appropriate indicator for a good bond of EDNi/DECu/NARloy-Z layers with the desired thickness of copper deposition in the SSME MCC manufacturing process. Furthermore, the results from this study appear to be applicable to any bonded joints that can be characterized by the parameters and assumptions used in this analysis.

Min, J. B.↗
NASA NTRS1998

Wide Panel Testing Technique for Evaluating Repair Weld Strengths

This paper describes a new tensile testing technique for evaluating the overall effect of a repair weld on the strength of a welded joint. Previously, repair weld strengths have been evaluated using one-inch width tensile specimens, but this technique does not capture all of the effects that result from a repair. The new technique involves testing of "wide panel" tensile specimens which contain the full length of a repair weld within a longer initial weld, allowing the specimen to capture the combined effects of residual stresses, local strength degradation, and load redistribution around a repair. The development of strains in the repair area of standard aluminum alloy specimens and new high-performance aluminum-lithium alloy specimens was observed and evaluated using photoelastic material. The results of this evaluation show an increased sensitivity to repair welding residual stresses in the aluminum-lithium alloy specimens.

Rogers, Patrick R.↗