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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Grainex Mar-M 247 Turbine Disk Life Study for NASA's High Temperature High Speed Turbine Seal Test Facility

An experimental and analytical fatigue life study was performed on the Grainex Mar-M 247 disk used in NASA s Turbine Seal Test Facility. To preclude fatigue cracks from growing to critical size in the NASA disk bolt holes due to cyclic loading at severe test conditions, a retirement-for-cause methodology was adopted to detect and monitor cracks within the bolt holes using eddy-current inspection. For the NASA disk material that was tested, the fatigue strain-life to crack initiation at a total strain of 0.5 percent, a minimum to maximum strain ratio of 0, and a bolt hole temperature of 649 C was calculated to be 665 cycles using -99.95 percent prediction intervals. The fatigue crack propagation life was calculated to be 367 cycles after implementing a safety factor of 2 on life. Thus, the NASA disk bolt hole total life or retirement life was determined to be 1032 cycles at a crack depth of 0.501 mm. An initial NASA disk bolt hole inspection at 665 cycles is suggested with 50 cycle inspection intervals thereafter to monitor fatigue crack growth.

Delgado, Irebert R.↗
NASA NTRS2000

Simulating Fatigue Crack Growth in Spiral Bevel Gears

The majority of helicopter transmission systems utilize spiral bevel gears to convert the horizontal power from the engine into vertical power for the rotor. Due to the cyclical loading on a gear's tooth, fatigue crack propagation can occur. In rotorcraft applications, a crack's trajectory determines whether the gear failure will be benign or catastrophic for the aircraft. As a result, the capability to predict crack growth in gears is significant. A spiral bevel gear's complex shape requires a three dimensional model of the geometry and cracks. The boundary element method in conjunction with linear elastic fracture mechanics theories is used to predict arbitrarily shaped three dimensional fatigue crack trajectories in a spiral bevel pinion under moving load conditions. The predictions are validated by comparison to experimental results. The sensitivity of the predictions to variations in loading conditions and crack growth rate model parameters is explored. Critical areas that must be understood in greater detail prior to predicting more accurate crack trajectories and crack growth rates in three dimensions are identified.

Spievak, Lisa E.↗
NASA NTRS2013

Engineering Evaluation of International Low Impact Docking System Latch Hooks

The international Low Impact Docking System (iLIDS) provides a structural arrangement that allows for visiting vehicles to dock with the International Space Station (ISS) (Fig 1). The iLIDS docking units are mechanically joined together by a series of active and passive latch hooks. In order to preserve docking capability at the existing Russian docking interfaces, the iLIDS latch hooks are required to conform to the existing Russian design. The latch hooks are classified as being fail-safe. Since the latch hooks are fail-safe, the hooks are not fracture critical and a fatigue based service life assessment will satisfy the structural integrity requirements. Constant amplitude fatigue testing to failure on four sets of active/passive iLIDS latch hooks was performed at load magnitudes of 10, 11, and 12 kips. Failure analysis of the hook fatigue failures identified multi-site fatigue initiation that was effectively centered about the hook mid-plane (consistent with the 3D model results). The fatigue crack initiation distribution implies that the fatigue damage accumulation effectively results in a very low aspect ratio surface crack (which can be simulated as thru-thickness crack). Fatigue damage progression resulted in numerous close proximity fatigue crack initiation sites. It was not possible to determine if fatigue crack coalescence occurs during cyclic loading or as result of the fast fracture response. The presence of multiple fatigue crack initiation sites on different planes will result in the formation of ratchet marks as the cracks coalesce. Once the stable fatigue crack becomes unstable and the fast fracture advances across the remaining ligament and the plane stress condition at a free-surface will result in failure along a 45 deg. shear plane (slant fracture) and the resulting inclined edge is called a shear lip. The hook thickness on the plane of fatigue crack initiation is 0.787". The distance between the shear lips on this plane was on the order of 0.48" and it was effectively centered about the mid-plane of the section. The numerous ratchet marks between the shear lips on the fracture initiation plane are indicative of multiple fatigue initiation sites within this region. The distribution of the fatigue damage about the centerline of the hook is consistent with the analytical results that demonstrate peak stress/strain response at the mid-plane that decreases in the direction of the hook outer surfaces. Scanning electron microscope images of the failed sections detected fatigue crack striations in close proximity to the free surface of the hook radius. These findings were documented at three locations on the fracture surface : 1) adjacent to the left shear lip, 2) adjacent to the right shear lip, and 3) near the centerline of the section. The features of the titanium fracture surface did not allow for a determination of a critical crack size via identification of the region where the fatigue crack propagation became unstable. The fracture based service life projections where benchmarked with strain-life analyses. The strainrange response in the hook radius was defined via the correlated finite element models and the modified method of universal slopes was incorporated to define the strain-life equation for the titanium alloy. The strain-life assessment confirmed that the fracture based projections were reasonable for the loading range of interest. Based upon the analysis and component level fatigue test data a preliminary service life capability for the iLIDS active and passive hooks of 2 lifetimes is projected (includes a scatter factor of 4).

Martinez, J.↗
NASA NTRS2018

From S-N to the Paris Law with a New Mixed-Mode Cohesive Fatigue Model

The relationship between fatigue life and fatigue crack propagation rate is explored with a new cohesive damage model. The parameters of the model are obtained from idealizations of S-N diagrams used in engineering design. The model is based on the hypothesis that both stable tearing damage and damage due to cyclic loading are representations of a density of microcracks and, therefore, a single damage variable can describe the state of damage. This assumption implies that the quasi-static cohesive law that describes tearing is also the envelope of the fatigue damage. Fatigue damage within the cohesive envelope is assumed to accumulate at a rate that depends on the displacement jumps. The fatigue model was implemented as a UMAT subroutine for Abaqus cohesive elements by adding fatigue damage accumulation to a cohesive model based on the Turon mixed-mode cohesive laws. The analyses were conducted using a simplified cyclic loading procedure in which the maximum applied load is kept constant and the computational expense of cycling the load is avoided. The predicted propagation rates in mode I and mixed mode were compared to experimental results for IM7/8552 graphite/epoxy tape. Several aspects of the results were investigated, including the effect of R-curves, the stress ratio R, and the difference between displacement control and force control.

Davila, Carlos G.↗
NASA NTRS2018

A Cohesive Fatigue Model Based on the S-N Diagram

The relationship between fatigue life and fatigue crack propagation rate is explored with a new cohesive damage model. The parameters of the model are obtained from idealizations of S-N diagrams used in engineering design. The model is based on the hypothesis that both stable tearing damage and damage due to cyclic loading are representations of a density of microcracks and, therefore, a single damage variable can describe the state of damage. This assumption implies that the quasi-static cohesive law that describes tearing is also the envelope of the fatigue damage. Fatigue damage within the cohesive envelope is assumed to accumulate at a rate that depends on the displacement jumps. The fatigue model was implemented as a UMAT subroutine for Abaqus cohesive elements by adding fatigue damage accumulation to a cohesive model based on the Turon quasi-static cohesive law. The analyses were conducted using a simplified cyclic loading procedure in which the maximum applied load is kept constant and the computational expense of cycling the load is avoided. The predicted propagation rates for a double cantilever beam (DCB) specimen were compared to experimental results for IM7/8552 graphite/epoxy tape.

Dávila, Carlos G.↗
DOE OSTI2020

Measurement of Fatigue and Static Crack Growth Rate of X65 Line Pipe Steel in 3.5% NaCl containing CO2 under Cathodic Polarization

X-65 Line pipe steel was investigated for susceptibility to environmentally assisted fatigue and static crack growth susceptibility in acidic environments at 1 atm and 4 atm pressures of CO₂. FCGR response as a function of frequency was similar for the two environments. The FCGR showed an increase with decrease in frequency highlighting that the material was susceptible to environmentally assisted cracking in the studied environment. A significant decrease in resistance to fatigue crack propagation was observed in the studied environments with respect to BS-7910 based in-air mean curves for steel.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Analytical and experimental investigation of aircraft metal structures reinforced with filamentary composites. Phase 2: Structural fatigue, thermal cycling, creep, and residual strength

Specimens representative of metal aircraft structural components reinforced with boron filamentary composites were manufactured and tested under cyclic loading, cyclic temperature, or continuously applied loading to evaluate some of the factors that affect structural integrity under cyclic conditions. Bonded, stepped joints were used throughout to provide composite-to-metal transition regions at load introduction points. Honeycomb panels with titanium or aluminum faces reinforced with unidirectional boron composite were fatigue tested at constant amplitude under completely reversed loading. Results indicated that the matrix material was the most fatigue-sensitive part of the design, with debonding initiating in the stepped joints. However, comparisons with equal weight all-metal specimens show a 10 to 50 times improved fatigue life. Fatigue crack propagation and residual strength were studied for several different stiffened panel concepts, and were found to vary considerably depending on the configuration. Composite-reinforced metal specimens were also subjected to creep and thermal cycling tests. Thermal cycling of stepped joint tensile specimens resulted in a ten percent decrease in residual strength after 4000 cycles.

Blichfeldt, B.↗
NASA NTRS1972

Determination of design allowable properties. Fracture of 2219-T87 aluminum alloy

A literature survey was conducted to provide a comprehensive report of available valid data on tensile properties, fracture toughness, fatigue crack propagation, and sustained load behavior of 2219-T87 aluminum alloy base metal and weldments, as applicable to manned spacecraft tankage. Most of the data found were from tests conducted at room temperature, -320 F and -423 F. Data are presented in graphical and tabular form, and areas in which data are lacking are established.

Engstrom, W. L.↗
NASA NTRS1972

Fracture of cylindrical and spherical shells containing a crack.

Fatigue and fracture of cylindrical and spherical shells containing a through crack and subjected to internal pressure or torsion are considered. The stress intensity factor ratios giving the effect of curvature are obtained as functions of a dimensionless shell parameter. By using the conventional plastic strip model the plastic zone size around the crack tip and the crack opening displacement are calculated. The calculated COD values are shown to be in good agreement with the experimental results. The fracture criterion of critical COD is verified by using the results of the burst tests in titanium and aluminum alloy cryogenic pressure vessels. Modified fatigue crack propagation models taking into account the bending effect in shells are introduced and are applied to the analysis of experimental data obtained from flat plates, and cylindrical shells under axial tension, internal pressure, and torsion. Finally, the paper includes the effect of humidity on the crack growth rate and the effect of load biaxiality on the rupture strength.

Erdogan, F.↗
NASA NTRS1973

Fatigue testing device

Anti-buckling assembly prevents buckling of sheet metal fatigue specimen when axial compressive load is applied. It provides for cyclic heating and cooling of specimen during testing. Assembly permits tests at two locations on specimen. Device has ports for visual, optical, or photographic monitoring of fatigue crack propagation in test specimen.

Eichenbrenner, F. E.↗
NASA NTRS1976

A reliability-based cost effective fail-safe design procedure

The authors have developed a methodology for cost-effective fatigue design of structures subject to random fatigue loading. A stochastic model for fatigue crack propagation under random loading has been discussed. Fracture mechanics is then used to estimate the parameters of the model and the residual strength of structures with cracks. The stochastic model and residual strength variations have been used to develop procedures for estimating the probability of failure and its changes with inspection frequency. This information on reliability is then used to construct an objective function in terms of either a total weight function or cost function. A procedure for selecting the design variables, subject to constraints, by optimizing the objective function has been illustrated by examples. In particular, optimum design of stiffened panel has been discussed.

Hanagud, S.↗
NASA NTRS1977

Fracture control of H-O engine components

An investigation was made to obtain the material characterization and fatigue crack propagation data necessary to establish the salient characteristics of a Ti-6Al-2.5Sn(ELI) alloy fuel pump impeller to be used in a cryogenic service environment. Testing variables considered were: coupon orientation, frequency, load range ratio, and temperature. Data analysis correlated crack propagation data from conventional laboratory coupons with data from a parallel sided rotating disk used to model rotor stresses. Four major design recommendations when bore regions of fuel pump impellers to be operated in cryogenic environments are to be relatively highly stressed are discussed.

Ryder, J. T.↗
NASA NTRS1977

Alloy design with oxide dispersoids and precipitates

The mechanical behavior of particle-strengthened alloys is reviewed. On the basis of this knowledge, it is concluded that second-phase particles, coherent or incoherent, can enhance the flow strength, creep resistance, and stress-rupture life of alloys. Unfortunately, particles are usually not beneficial alloy-design elements if enhanced uniaxial ductility, plane-strain ductility, stress-rupture ductility, and toughness are called for. Such properties as fatigue-crack propagation resistance appear to require, for example, both high strength and high ductility, a situation which can come to pass only when the perennial conflict between strength and ductility is resolved in particle-strengthened systems in particular and in any other material system in general. Wherever possible, the role of coherent and incoherent particles in alloy design is distinguished.

Tien, J. K.↗
NASA NTRS1979

Interaction of laser-induced stress waves with metals

An investigation of the effect of high intensity laser induced stress waves on the hardness and tensile strength of 2024 and 7075 aluminum and on the fatigue properties of 7075 aluminum were investigated. Laser shocking increases the hardness of the underaged 2024-T351 but has little or no effect on the peak aged 2024-T351 and 7075-T651 or the overaged 7075-T73. The fretting fatigue life of fastener joints of 7075-T6 was increased by orders of magnitude by laser shocking the region around the fastener hole; the fatigue crack propagation rates were decreased by laser shocking.

Clauer, A. H.↗