Critical combinations of shear and longitudinal direct stress for long plates with transverse curvature
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Additional information was added to a growing data base from which estimates of finite element model complexities can be made with respect to thermal stress analysis. The manner in which temperatures were smeared to the finite element grid points was examined from the point of view of the impact on thermal stress calculations. The general comparison of calculated and measured thermal stresses is guite good and there is little doubt that the finite element approach provided by NASTRAN results in correct thermal stress calculations. Discrepancies did exist between measured and calculated values in the skin and the skin/frame junctures. The problems with predicting skin thermal stress were attributed to inadequate temperature inputs to the structural model rather than modeling insufficiencies. The discrepancies occurring at the skin/frame juncture were most likely due to insufficient modeling elements rather than temperature problems.
Experimental creep, temperature, and strain data resulting from a laboratory experiment on a built-up aluminum/titanium structure are presented. The structure and the experiment are described in detail. A heating and loading experiment lasting approximately six hours is conducted on a test structure. Considerable creep strain resulted from compressive stresses in the heated skin. Large residual stresses were found after the experiment was completed. The residual stresses in the substructure frames were large enough to preclude further cycles of creep experiments with this built-up structure because of concern that the frame webs would buckle.
Charts are presented for the coefficients in formulas for the critical compressive stress at which cross-sectional distortion begins in a thin-wall member with either a channel section or a Z-section with identical flanges. The energy method of Timoshenko was used in the theoretical calculations required for the construction of the charts. The deflection equations were carefully selected to give good accuracy. The calculation of the critical compressive stress at stresses beyond the elastic range is briefly discussed. In order to demonstrate the use of the formulas and the charts in engineering calculations, two illustrative problems are included.
Preflight thermal stress analysis of the space shuttle orbiter wing skin panel and the thermal protection system (TPS) was performed. The heated skin panel analyzed was rectangular in shape and contained a small square cool region at its center. The wing skin immediately outside the cool region was found to be close to the state of elastic instability in the chordwise direction based on the conservative temperature distribution. The wing skin was found to be quite stable in the spanwise direction. The potential wing skin thermal instability was not severe enough to tear apart the strain isolation pad (SIP) layer. Also, the preflight thermal stress analysis was performed on the TPS tile under the most severe temperature gradient during the simulated reentry heating. The tensile thermal stress induced in the TPS tile was found to be much lower than the tensile strength of the TPS material. The thermal bending of the TPS tile was not severe enough to cause tearing of the SIP layer.
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Two brazed Rene 41 honeycomb panels that would incorporate a frame element were designed, fabricated and tested. The panels were representative of the lower surface of an advanced space transportation vehicle. The first panel was a two span panel supported by a center frame and on edges parallel to it. The second panel was a two span panel supported by a center frame and on edges parallel to it. The second panel was a three span panel supported on two frames and on edges parallel to the frames. Each panel had its outer skin slotted to reduce the thermal stresses of the panel skins. The first panel was tested under simulated boost conditions that included liquid hydrogen exposure of the frame and inner skin and radiant heat to 478K on the outer skins. The first panel was tested to investigate the effect of thermal stresses in skins and core caused by the panel being restrained by a cold integral frame and to observe the effects of frost formation and possible liquid air development in and around outer skin slots.
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A Mach 6 flight was simulated in order to examine heating effects on three frame/skin specimens. The specimens included: a titanium truss frame with a lockalloy skin; a stainless steel z-frame with a lockalloy skin; and a titanium z-frame with a lockalloy skin. Thermal stresses and temperature were measured on these specimens for the purpose of examining their efficiency, performance, and integrity. Measured thermal stresses were examined with respect to material yield strengths, buckling criteria, structural weight, and geometric locations. Principal thermal stresses were studied from the standpoint of uniaxial stress assumptions. Measured thermal stresses were compared to predicted values.
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Protective coatings effect on stress corrosion properties of supersonic transport skin materials
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