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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 NTRS2008

Weld Residual Stress and Distortion Analysis of the ARES I-X Upper Stage Simulator (USS)

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The Ares system of space launch vehicles is the US National Aeronautics and Space Administration s plan for replacement of the aging space shuttle. The new Ares space launch system is somewhat of a combination of the space shuttle system and the Saturn launch vehicles used prior to the shuttle. Here, a series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on fatigue and fracture life. While the main focus of this paper is a discussion of the weld modeling procedures and results for the USS, a short summary of the CIFS assessment is provided.

Raju, Ivatury↗
NASA NTRS2001

Cryogenic Treatment of Al-Li Alloys for Improved Weldability, Repairability, and Reduction of Residual Stresses

Service performance has shown that cryogenic treatment of some metals provides improved strength, fatigue life, and wear resistance to the processed material. Effects such as these were initially discovered by NASA engineers while evaluating spacecraft that had returned from the cold vacuum of space. Factors such as high cost, poor repairability, and poor machinability are currently prohibitive for wide range use of some aerospace aluminum alloys. Application of a cryogenic treatment process to these alloys is expected provide improvements in weldability and weld properties coupled with a reduction in repairs resulting in a significant reduction in the cost to manufacture and life cycle cost of aerospace hardware. The primary purpose of this effort was to evaluate the effects of deep cryogenic treatment of some aluminum alloy plate products, welds, and weld repairs, and optimize a process for the treatment of these materials. The optimized process is being evaluated for improvements in properties of plate and welds, improvements in weldability and repairability of treated materials, and as an alternative technique for the reduction of residual stresses in repaired welds. This paper will present the results of testing and evaluation conducted in this effort. These results will include assessments of changes in strength, toughness, stress corrosion susceptability, weldability, repairability, and reduction in residual stresses of repaired welds.

Malone, Tina W.↗
NASA NTRS2008

Ares I-X Upper Stage Simulator Residual Stress Analysis

The structural analyses described in the present report were performed in support of the NASA Engineering and Safety Center (NESC) Critical Initial Flaw Size (CIFS) assessment for the Ares I-X Upper Stage Simulator (USS) common shell segment. An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The Ares system of space launch vehicles is the US National Aeronautics and Space Administration s plan for replacement of the aging space shuttle. The new Ares space launch system is somewhat of a combination of the space shuttle system and the Saturn launch vehicles used prior to the shuttle. Here, a series of weld analyses are performed to determine the residual stresses in a critical region of the USS. Weld residual stresses both increase constraint and mean stress thereby having an important effect on fatigue and fracture life. The results of this effort served as one of the critical load inputs required to perform a CIFS assessment of the same segment.

Raju, Ivatury S.↗
NASA NTRS2013

Quantification of Residual Stress from Photonic Signatures of Fused Silica

A commercially available grey-field polariscope (GFP) instrument for photoelastic examination is used to assess impact damage inflicted upon the outer-most pane of Space Shuttle windows made from fused silica. A method and apparatus for calibration of the stress-optic coefficient using four-point bending is discussed. The results are validated on known material (acrylic) and are found to agree with literature values to within 6%. The calibration procedure is then applied to fused-silica specimens and the stress-optic coefficient is determined to be 2.43 +/- 0.54 x 10(exp -12)/Pa. Fused silica specimens containing impacts artificially made at NASA's Hypervelocity Impact Technology Facility (HIT-F), to simulate damage typical during space flight, are examined. The damage sites are cored from fused silica window carcasses and examined with the GFP. The calibrated GFP measurements of residual stress patterns surrounding the damage sites are presented. Keywords: Glass, fused silica, photoelasticity, residual stress

Cramer, K. Elliott↗
NASA NTRS1987

Accelerated crack growth, residual stress, and a cracked zinc coated pressure shell

During a partial inspection of a 42 year old, operating, pressurized wind tunnel at NASA-Ames Research Center, a surface connected defect 114 in. long having an indicated depth of a 0.7 in. was detected. The pressure shell, constructed of a medium carbon steel, contains approximately 10 miles of welds and is cooled by flowing water over its zinc coated external surface. Metallurgical and fractographic analysis showed that the actual detect was 1.7 in. deep, and originated from an area of lack of weld penetration. Crack growth studies were performed on the shell material in the laboratory under various loading rates, hold times, and R-ratios with a simulated shell environment. The combination of zinc, water with electrolyte, and steel formed an electrolytic cell which resulted in an increase in cyclic crack growth rate by as much as 500 times over that observed in air. It was concluded that slow crack growth occurred in the pressure shell by a combination of stress corrosion cracking due to the welding residual stress and corrosion fatigue due to the cyclic operating stress.

Dittman, Daniel L.↗
NASA NTRS1990

Scanning electron acoustic microscopy of indentation-induced cracks and residual stresses in ceramics

The ability of scanning electron acoustic microscopy (SEAM) to characterize ceramic materials is assessed. SEAM images of Vickers indentations in SiC whisker-reinforced alumina clearly reveal not only the radial cracks, the length of which can be used to estimate the fracture toughness of the material, but also reveal strong contrast, interpreted as arising from the combined effects of lateral cracks and the residual stress field left in the SiC whisker-reinforced alumina by the indenter. The strong contrast is removed after the material is heat treated at 1000 C to relieve the residual stresses around the indentations. A comparison of these observations with SEAM and reflected polarized light observations of Vickers indentations in soda-lime glass both before and after heat treatment confirms the interpretation of the strong contrast.

Cantrell, John H.↗
NASA NTRS1992

Scanning electron acoustic microscopy of residual stresses in ceramics: Theory and experiment

Several reviews have highlighted a number of applications of scanning electron acoustic microscopy (SEAM) to metals and semiconductors which show that SEAM can provide new information on surface and near-surface features of such materials, but there have been few studies attempting to determine the capabilities of SEAM for characterizing ceramic materials. We have recently observed image contrast in SEAM from residual stress fields induced in brittle materials by Vickers indentations that is strongly dependent on the electron beam chopping frequency. We have also recently developed a three-dimensional mathematical model of signal generation and contrast in SEAM, appropriate to the brittle materials studied, that we use as a starting point in this paper for modeling the effect of residual stress fields on the generated electron acoustic signal. The influence of the electron beam chopping frequency is also considered under restrictive assumptions.

Cantrell, John H.↗
NASA NTRS1974

Texturing and residual stress in metals as a result of sliding

Pole figures of the texturing produced by friction in the alloys Cu - 10 at. % Sn, Cu - 10 at. % Si, 440 C stainless steel, and AISI 52100 bearing steel were obtained with an energy-dispersive X-ray diffractometer. While the texturing behavior of these alloys is generally similar to that of pure metals, the 52100 steel and the Cu5Si phase of Cu - 10 at. % Si show no texturing at the loads and speeds used in this experiment. Photographic methods were used in an attempt to measure the uniform residual stress in the wear tracks produced on some pure metals. The stress in copper and iron was, however, below the limit of detectability - about 4.3 x 10 to the 7th power N/sq m (6000 psi). Line broadening under all test conditions in the case of copper and at high load and speed conditions in iron is attributed, at least in part, to the reduction of crystallite size and, perhaps, to nonuniform residual stress, as well.

Wheeler, D. R.↗
NASA NTRS1986

Residual stress measurements in carbon steel

External dc magnetic field-induced changes in natural velocity of Rayleigh surface waves were measured in steel specimens under various stress conditions. The low field slopes of curves representing the fractional changes of natural velocity were proved to provide correct stress information in steels with different metallurgical properties. The slopes of curves under uniaxial compression, exceeding about one third of the yield stress, fell below zero in all the specimens when magnetized along the stress axis. The slopes under tension varied among different steels but remained positive in any circumstances. The stress effect was observed for both applied and residual stress. A physical interpretation of these results is given based on the stress-induced domain structure changes and the delta epsilon effect. Most importantly, it is found that the influence of detailed metallurgical properties cause only secondary effects on the obtained stress information.

Heyman, J. S.↗
NASA NTRS1969

Techniques for controlling warpage and residual stresses in welded structures

Thermal pattern alteration technique controls both distortion and residual stresses in aluminum weldments. Cryogenic liquids and auxiliary heat sources are used to produce contraction and expansion of metal in the vicinity of the weld in such a manner as to counterbalance expansion and contraction caused by welding.

Cole, D. Q.↗
NASA NTRS1983

Residual stress in plasma sprayed ceramic turbine tip and gas path seal specimens

The residual stresses in a ceramic sheet material used for turbine blade tip gas path seals, were estimated. These stresses result from the plasma spraying process which leaves the surface of the sheet in tension. To determine the properties of plasma sprayed ZrO2-Y2O3 sheet material, its load deflection characteristics were measured. Estimates of the mechanical properties for sheet materials were found to differ from those reported for plasma sprayed bulk materials.

Hendricks, R. C.↗
NASA NTRS1991

Concurrent tailoring of fabrication process and interphase layer to reduce residual stresses in metal matrix composites

A methodology is presented to reduce the residual matrix stresses in continuous fiber metal matrix composites (MMC) by optimizing the fabrication process and interphase layer characteristics. The response of the fabricated MMC was simulated based on nonlinear micromechanics. Application cases include fabrication tailoring, interphase tailoring, and concurrent fabrication-interphase optimization. Two composite systems, silicon carbide/titanium and graphite/copper, are considered. Results illustrate the merits of each approach, indicate that concurrent fabrication/interphase optimization produces significant reductions in the matrix residual stresses and demonstrate the strong coupling between fabrication and interphase tailoring.

Saravanos, D. A.↗
NASA NTRS1993

Electromechanical Apparatus Measures Residual Stress

Nondestructive test exploits relationship between stress and eddy-current-probe resistance. Yields data on residual stress or strain in metal tension/compression specimen (stress or strain remaining in specimen when no stress applied from without). Apparatus is assembly of commercial equipment: tension-or-compression testing machine, eddy-current probe, impedance gain-and-phase analyzer measuring impedance of probe coil, and desktop computer, which controls other equipment and processes data received from impedance gain-and-phase analyzer.

Chern, Engmin J.↗
NASA NTRS1992

Measurment Of Residual Stress In Ferromagnetic Materials

Magnetoacoustic (MAC) and magnetoacoustic emission (MAE) techniques combined to provide complete characterization of residual stresses in ferromagnetic structural materials. Combination of MAC and MAE techniques makes it possible to characterize residual tension and compression without being limited by surface conditions and unavailability of calibration standards. Significant in field of characterization of materials as well as detection of fatigue failure.

Namkung, Min↗
NASA NTRS2002

Properties of the Residual Stress of the Temporally Filtered Navier-Stokes Equations

The development of a unifying framework among direct numerical simulations, large-eddy simulations, and statistically averaged formulations of the Navier-Stokes equations, is of current interest. Toward that goal, the properties of the residual (subgrid-scale) stress of the temporally filtered Navier-Stokes equations are carefully examined. Causal time-domain filters, parameterized by a temporal filter width 0 less than Delta less than infinity, are considered. For several reasons, the differential forms of such filters are preferred to their corresponding integral forms; among these, storage requirements for differential forms are typically much less than for integral forms and, for some filters, are independent of Delta. The behavior of the residual stress in the limits of both vanishing and in infinite filter widths is examined. It is shown analytically that, in the limit Delta to 0, the residual stress vanishes, in which case the Navier-Stokes equations are recovered from the temporally filtered equations. Alternately, in the limit Delta to infinity, the residual stress is equivalent to the long-time averaged stress, and the Reynolds-averaged Navier-Stokes equations are recovered from the temporally filtered equations. The predicted behavior at the asymptotic limits of filter width is further validated by numerical simulations of the temporally filtered forced, viscous Burger's equation. Finally, finite filter widths are also considered, and a priori analyses of temporal similarity and temporal approximate deconvolution models of the residual stress are conducted.

Pruett, C. D.↗