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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
DOE OSTI2023

Effect of sample size on the maximum value distribution of fatigue driving forces in metals and alloys

An analytical framework is presented to predict the effects of sample size on the maximum value distribution (MVD) of the driving forces for fatigue crack formation in metals and alloys. The distribution of the maximum driving force for fatigue crack formation over the domain follows the generalized extreme value theory in the limit as the domain size increases to infinity. Here, a simulation-based analysis of microstructure influences on fatigue resistance for polycrystalline metals and alloys is very costly, and reaching those limits is intractable. This work models the MVD of Fatigue Indicator Parameters (FIPs), which serve as surrogate measures for the driving force for fatigue crack formation, at finite sample sizes prior to their convergence to a limiting extreme value distribution. Large-scale crystal plasticity finite element (CPFE) simulations of FCC Al 7075-T6 with microstructure realizations of various sizes are incorporated to calibrate and evaluate the developed framework, and a total of ∼6.5 million grains of Al 7075-T6 are examined. The calibrated analytical solution agrees well with the brute force Monte Carlo simulation results extracted from the CPFE simulations. Furthermore, the developed formulation can predict the MVD of FIPs for different sample sizes using a size-dependent parameter, and it is capable of accurately extrapolating the MVD of FIPs for much larger microstructure sample sizes than the size used for its calibration.

Crystal plasticity↗
NASA NTRS1985

Thermal-mechanical fatigue test apparatus for metal matrix composites and joint attachments

Two thermal-mechanical fatigue (TMF) test facilities were designed and developed, one to test tungsten fiber reinforced metal matrix composite specimens at temperature up to 1430C (2600F) and another to test composite/metal attachment bond joints at temperatures up to 760C (1400 F). The TMF facility designed for testing tungsten fiber reinforced metal matrix composites permits test specimen temperature excursions from room temperature to 1430C (2600F) with controlled heating and loading rates. A strain-measuring device measures the strain in the test section of the specimen during each heating and cooling cycle with superimposed loads. Data is collected and recorded by a computer. The second facility is designed to test composite/metal attachment bond joints and to permit heating to a maximum temperature of 760C (1400F) within 10 min and cooling to 150C (300F) within 3 min. A computer controls specimen temperature and load cycling.

Westfall, L. J.↗
NASA NTRS1988

Thermal-mechanical fatigue test apparatus for metal matrix composites and joint attachments

Two thermal-mechanical fatigue (TMF) test facilities were designed and developed, one to test tungsten fiber reinforced metal matrix composite specimens at temperature up to 1430C (2600F) and another to test composite/metal attachment bond joints at temperatures up to 760F (1400F). The TMF facility designed for testing tungsten fiber reinforced metal matrix composites permits test specimen temperature excursions from room temperature to 1430C (2600F) with controlled heating and loading rates. A strain-measuring device measures the strain in the test section of the specimen during each heating and cooling cycle with superimposed loads. Data is collected and recorded by a computer. The second facility is designed to test composite/metal attachment bond joints and to permit heating to a maximum temperature of 760C (1400F) within 10 min and cooling to 150C (300F) within 3 min. A computer controls specimen temperature and load cycling.

Westfall, Leonard J.↗
NASA NTRS1975

Fatigue performance of metal-lined graphite/epoxy pressure vessels

Using an ultrahigh-strength graphite fiber, a program was started to develop a thin metal-lined fiber/epoxy pressure vessel that would have a fatigue life of over 1000 cycles. First, the performance factor of the fiber/epoxy composite was found to be 351 kN m/kg from the average of 18 rubber-lined pressure vessels. Then, both aluminum- and titanium-lined vessels were filament wound with the graphite fiber in an epoxy matrix. Several of these metal-lined vessels were subjected to hydraulic fatigue testing to about 50% of their expected burst pressures. The average fatigue life of the aluminum-lined vessels was 462 cycles; the average for the titanium-lined vessels was 2190 cycles.

Hamstad, M. A.↗
NASA NTRS1992

Detection and characterization of fatigue cracks in thin metal plates by low frequency resonant model analysis

Low-frequency resonant model analysis, a technique for the detection and characterization of fatigue cracks in thin metal plates, which could be adapted to rapid scan or large area testing, is considered. Experimental data displaying a direct correlation between fatigue crack geometry and resonance frequency for the second vibrational plate mode are presented. FEM is used to calculate the mechanical behavior of the plates, and provides a comparison basis for the experimentally determined resonance frequency values. The waveform of the acoustic emission generated at the resonant frequency is examined; it provides the basis for a model of the interaction of fatigue crack faces during plate vibration.

Wincheski, B.↗
NASA NTRS1993

Fatigue-life behavior and matrix fatigue crack spacing in unnotched SCS-6/Timetal 21S metal matrix composites

Fatigue tests of the SCS-6/Timetal 21S composite system were performed to characterize the fatigue behavior for unnotched conditions. The stress-life behavior of the unnotched (9/90)2s laminates was investigated for stress ratios of R = 0.1 and R = 0.3. The occurrence of matrix cracking was also examined in these specimens. This revealed multiple matrix crack initiation sites throughout the composite, as well as evenly spaced surface cracks along the length of the specimens. No difference in fatigue lives were observed for stress ratios of R = 0.1 and R = 0.3 when compared on a stress range basis. The unnotched SCS-6/Timetal 21S composites had shorter fatigue lives than the SCS-6/Ti-15-3 composites, however the neat Timetal 21S matrix material had a longer fatigue life than the neat Ti-15-3.

Ward, G. T.↗
NASA NTRS1990

Corrosion fatigue crack propagation in metals

This review assesses fracture mechanics data and mechanistic models for corrosion fatigue crack propagation in structural alloys exposed to ambient temperature gases and electrolytes. Extensive stress intensity-crack growth rate data exist for ferrous, aluminum and nickel based alloys in a variety of environments. Interactive variables (viz., stress intensity range, mean stress, alloy composition and microstructure, loading frequency, temperature, gas pressure and electrode potential) strongly affect crack growth kinetics and complicate fatigue control. Mechanistic models to predict crack growth rates were formulated by coupling crack tip mechanics with occluded crack chemistry, and from both the hydrogen embrittlement and anodic dissolution/film rupture perspectives. Research is required to better define: (1) environmental effects near threshold and on crack closure; (2) damage tolerant life prediction codes and the validity of similitude; (3) the behavior of microcrack; (4) probes and improved models of crack tip damage; and (5) the cracking performance of advanced alloys and composites.

Gangloff, Richard P.↗
NASA NTRS1995

Predicting Fatigue Lives Of Metal-Coated Nickel-Alloy Parts

LAYER computer program performs thermomechanical-fatigue-life prediction for coated, nickel-based anisotropic materials. Intended to provide gas-turbine-airfoil designers with means to accurately project service lifetimes. Written in FORTRAN 77.

Mcgaw, Michael A.↗
DOE OSTI2023

Implications of Fatigue-Crack Healing in Nanocrystalline Metals [Slides]

Under high-cycle fatigue conditions, a fatigue crack in nanocrystalline Pt was observed to undergo healing. The healing appears to occur by cold welding, facilitated by grain boundary migration, and also by local closure stresses. The healing may help explain several observations: role of air (or vacuum) on fatigue life, impeded subsurface fatigue cracking, apparent flaw healing in sub-critical cycling of ceramics, the existence of a fatigue threshold, and the role of vacuum on the fatigue threshold.

36 MATERIALS SCIENCE↗
NASA NTRS1997

A Statistical Simulation Approach to Safe Life Fatigue Analysis of Redundant Metallic Components

This paper introduces a dual active load path fail-safe fatigue design concept analyzed by Monte Carlo simulation. The concept utilizes the inherent fatigue life differences between selected pairs of components for an active dual path system, enhanced by a stress level bias in one component. The design is applied to a baseline design; a safe life fatigue problem studied in an American Helicopter Society (AHS) round robin. The dual active path design is compared with a two-element standby fail-safe system and the baseline design for life at specified reliability levels and weight. The sensitivity of life estimates for both the baseline and fail-safe designs was examined by considering normal and Weibull distribution laws and coefficient of variation levels. Results showed that the biased dual path system lifetimes, for both the first element failure and residual life, were much greater than for standby systems. The sensitivity of the residual life-weight relationship was not excessive at reliability levels up to R = 0.9999 and the weight penalty was small. The sensitivity of life estimates increases dramatically at higher reliability levels.

Matthews, William T.↗
NASA NTRS1991

Modal analysis for characterization of fatigue cracks in thin metal plates

Detailed experimental investigation and numerical analysis were performed on the characterization of fatigue cracks in thin aluminum alloys by a low frequency resonant modal analysis technique. The resonance frequency of plate modes is altered by the presence of fatigue cracks. This frequency shift was analyzed using a finite element approach and the results were compared to experimental data. Acoustic sensors were used to detect the fatigue cracks which were stimulated by standing waves in 0.1 cm aluminum alloy plates. The response of several different sensors to the crack noise was studied, as was the response at higher order modes. It was found that critical crack information can be obtained from the amplitude and phase of the emitted signal with respect to that of the external driving force.

Wincheski, B.↗
NASA NTRS1991

Environment enhanced fatigue of advanced aluminum alloys and metal matrix composites

The environmental fatigue crack propagation behavior of advanced Al-Li-Cu based alloys and metal matrix composites is being characterized. Aqueous NaCl and water vapor, which produce atomic hydrogen by reactions on clean crack surfaces, are emphasized. The effects of environment sensitive crack closure, stress ratio, and precipitate microstructure are assessed. Mechanistic models are sought for intrinsic crack tip damage processes to enable predictions of cracking behavior outside of the data, metallurgical improvements in material cracking resistance, and insight on hydrogen compatibility.

Slavik, Donald C.↗
NASA NTRS2005

Effectiveness of Shot Peening in Suppressing Fatigue Cracking at Non-Metallic Inclusions in Udimet(trademark) 720

The fatigue lives of modern powder metallurgy disk alloys can be reduced by over an order of magnitude by surface cracking at inherent non-metallic inclusions. The objective of this work was to study the effectiveness of shot peening in suppressing LCF crack initiation and growth at surface nonmetallic inclusions. Inclusions were carefully introduced at elevated levels during powder metallurgy processing of the nickel-base disk superalloy Udimet 720. Multiple strain-controlled fatigue tests were then performed on machined specimens at 427 and 650 C in peened and unpeened conditions. Analyses were performed to compare the low cycle fatigue lives and failure initiation sites as a function of inclusion content, shot peening, and fatigue conditions. A large majority of the failures in as-machined specimens with introduced inclusions occurred at cracks initiating from inclusions intersecting the specimen surface. The inclusions could reduce fatigue life by up to 100X. Large inclusions had the greatest effect on life in tests at low strain ranges and high strain ratios. Shot peening can be used to improve life in these conditions by reducing the most severe effects of inclusions.

Barrie, Robert L.↗
NASA NTRS1993

Environment enhanced fatigue crack propagation in metals: Inputs to fracture mechanics life prediction models

This report is a critical review of both environment-enhanced fatigue crack propagation data and the predictive capabilities of crack growth rate models. This information provides the necessary foundation for incorporating environmental effects in NASA FLAGRO and will better enable predictions of aerospace component fatigue lives. The review presents extensive literature data on 'stress corrosion cracking and corrosion fatigue.' The linear elastic fracture mechanics approach, based on stress intensity range (Delta(K)) similitude with microscopic crack propagation threshold and growth rates, provides a basis for these data. Results are presented showing enhanced growth rates for gases (viz., H2 and H2O) and electrolytes (e.g. NaCl and H2O) in aerospace alloys including: C-Mn and heat treated alloy steels, aluminum alloys, nickel-based superalloys, and titanium alloys. Environment causes purely time-dependent accelerated fatigue crack growth above the monotonic load cracking threshold (KIEAC) and promotes cycle-time dependent cracking below (KIEAC). These phenomenon are discussed in terms of hydrogen embrittlement, dissolution, and film rupture crack tip damage mechanisms.

Gangloff, Richard P.↗