Fatigue behavior of a fusion welded Ti 8A1 1M0 1V simulated wing structure under the environment of a supersonic transport
Fatigue behavior of fusion welded structural assembly with supersonic transport application
STRUCTURAL FATIGUE↗
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Fatigue of composites
The failure mechanisms in the fatigue of composite materials are analyzed in terms of the requirements for designing fatigue-critical composite structures. Fiber reinforced polymers, fiber reinforced metals, fatigue of composite structures, and composite design considerations are discussed. It is concluded that composite materials offer the engineer the opportunity for tailoring stiffness in different directions for designing dynamic components.
Salkind, M. J.↗
Excitation, response, and fatigue life estimation methods for the structural design of externally blown flaps
Means for predicting the fluctuating pressures acting on externally blown flap surfaces are developed on the basis of generalizations derived from non-dimensionalized empirical data. Approaches for estimation of the fatigue lives of skin-stringer and honeycomb-core sandwich flap structures are derived from vibration response analyses and panel fatigue data. Approximate expressions for fluctuating pressures, structural response, and fatigue life are combined to reveal the important parametric dependences. The two-dimensional equations of motion of multi-element flap systems are derived in general form, so that they can be specialized readily for any particular system. An introduction is presented of an approach to characterizing the excitation pressures and structural responses which makes use of space-time spectral concepts and promises to provide useful insights, as well as experimental and analytical savings.
Ungar, E. E.↗
Acoustic fatigue life prediction for non-linear structures
Using an approach based on a time domain analysis, a method of equivalent linearization is applied for an estimation of the strain response of complex nonlinear structures having nearly arbitrary complexity. Fatigue lives estimated for a nonlinear beam with random excitation using the approximate method were compared with results obtained using a conventional numerical simulation, yielding nearly identical results.
Sun, J. Q.↗
Solidification Effects in MAR-M246(Hf) Alloy
Fatigue properties degraded with crystallographic orientations greater than 10 degrees from {001} axis. Influence of solidification and heat-treatment parameters on structure and fatigue properties of nickel-based superalloy MAR-M246(Hf) described in 24-page report. Superalloys have high strength and corrosion resistance at temperatures up to 1,400 degrees C; their uses range from petrochemical equipment to marine, industrial, aircraft, and vehicular gas turbines.
Johnston, M. H.↗
Ultrasonic technique for detection and measurement of fatigue cracks
Ultrasonic system for detection and measurement of fatigue cracks in notched steel alloys
ULTRASONICS↗
Advances in Fatigue and Fracture Mechanics Analyses for Aircraft Structures
This paper reviews some of the advances that have been made in stress analyses of cracked aircraft components, in the understanding of the fatigue and fatigue-crack growth process, and in the prediction of residual strength of complex aircraft structures with widespread fatigue damage. Finite-element analyses of cracked structures are now used to determine accurate stress-intensity factors for cracks at structural details. Observations of small-crack behavior at open and rivet-loaded holes and the development of small-crack theory has lead to the prediction of stress-life behavior for components with stress concentrations under aircraft spectrum loading. Fatigue-crack growth under simulated aircraft spectra can now be predicted with the crack-closure concept. Residual strength of cracked panels with severe out-of-plane deformations (buckling) in the presence of stiffeners and multiple-site damage can be predicted with advanced elastic-plastic finite-element analyses and the critical crack-tip-opening angle (CTOA) fracture criterion. These advances are helping to assure continued safety of aircraft structures.
Newman, J. C., Jr.↗
Intrinsic fatigue crack growth rates for Al-Li-Cu-Mg alloys in vacuum
The influences of microstructure and deformation mode on inert environment intrinsic fatigue crack propagation were investigated for Al-Li-Cu-Mg alloys AA2090, AA8090, and X2095 compared to AA2024. The amount of coherent shearable delta-prime (Al3Li) precipitates and extent of localized planar slip deformation were reduced by composition (increased Cu/Li in X2095) and heat treatment (double aging of AA8090). Intrinsic growth rates, obtained at high constant K(max) to minimize crack closure and in vacuum to eliminate any environmental effect, were alloy dependent; da/dN varied up to tenfold based on applied Delta-K or Delta-K/E. When compared based on a crack tip cyclic strain or opening displacement parameter, growth rates were equivalent for all alloys except X2095-T8, which exhibited unique fatigue crack growth resistance. Tortuous fatigue crack profiles and large fracture surface facets were observed for each Al-Li alloy independent of the precipitates present, particularly delta-prime, and the localized slip deformation structure. Reduced fatigue crack propagation rates for X2095 in vacuum are not explained by either residual crack closure or slip reversibility arguments; the origin of apparent slip band facets in a homogeneous slip alloy is unclear.
Slavik, D. C.↗
Estimation of Sonic Fatigue by Reduced-Order Finite Element Based Analyses
A computationally efficient, reduced-order method is presented for prediction of sonic fatigue of structures exhibiting geometrically nonlinear response. A procedure to determine the nonlinear modal stiffness using commercial finite element codes allows the coupled nonlinear equations of motion in physical degrees of freedom to be transformed to a smaller coupled system of equations in modal coordinates. The nonlinear modal system is first solved using a computationally light equivalent linearization solution to determine if the structure responds to the applied loading in a nonlinear fashion. If so, a higher fidelity numerical simulation in modal coordinates is undertaken to more accurately determine the nonlinear response. Comparisons of displacement and stress response obtained from the reduced-order analyses are made with results obtained from numerical simulation in physical degrees-of-freedom. Fatigue life predictions from nonlinear modal and physical simulations are made using the rainflow cycle counting method in a linear cumulative damage analysis. Results computed for a simple beam structure under a random acoustic loading demonstrate the effectiveness of the approach and compare favorably with results obtained from the solution in physical degrees-of-freedom.
Rizzi, Stephen A.↗
A Digital Twin Feasibility Study (Part II):Non-Deterministic Predictions of Fatigue Life Using In-Situ Diagnostics and Prognostics
The Digital Twin (DT) concept has the potential to revolutionize the way systems and their components are designed, managed, maintained, and operated across a vast number of fields from engineering to healthcare. The focus of this work is the implementation of DT for the health management of fatigue critical structures. This paper is the second part of a two-part series. The first of the series demonstrated the use of multi-scale, initiation-to-failure crack growth modeling to form non-deterministic predictions of fatigue life. In this second part, a general method for reducing uncertainty in fatigue life predictions is presented that couples in-situ diagnostics and prognostics in a probabilistic framework. Monte Carlo methods and high-fidelity finite element models are used to (i) generate probabilistic estimates of crack state throughout the life of the same geometrically complex test specimen and (ii) predict fatigue life with decreasing uncertainty as more of these diagnoses are obtained. The ability to predict accurately and in the presence of uncertainty is demonstrated, suggesting that the proposed DT method is feasible for fatigue life prognosis and should be pursued further with a focus on increasing application realism.
Patrick E Leser↗
Metal aircraft structural elements reinforced with graphite filamentary composites
Strain compatibility equations are used to evaluate the thermal stresses existing when unidirectional graphite composites are bonded to aluminum structures. Based on thermal stresses and optimum placement of the composite, skin-stringer aluminum panels are optimized for minimum weight compression panels with selective composite reinforcement. Composite reinforced skin-stringer panels are thermal cycled to determine the effect of thermal fatigue on structural integrity. Both cycled and uncycled panels are tested in compression and tension. Test results are correlated with predicted loads. Use of filamentary graphite composites is an efficient method of reinforcing metal structures, but care must be taken to minimize thermal stresses.
Berg, K. R.↗
Probability of failure prediction for step-stress fatigue under sine or random stress
A previously proposed cumulative fatigue damage law is extended to predict the probability of failure or fatigue life for structural materials with S-N fatigue curves represented as a scatterband of failure points. The proposed law applies to structures subjected to sinusoidal or random stresses and includes the effect of initial crack (i.e., flaw) sizes. The corrected cycle ratio damage function is shown to have physical significance.
Lambert, R. G.↗
Results of inphase axial-torsional fatigue experiments on 304 stainless steel
A series of axial-torsional, inphase, strain-controlled, low-cycle fatigue tests were performed at room temperature on tubular specimens of 304 stainless steel. The program was conducted in cooperation with the task group on multiaxial fatigue research of ASTM committee E-09. The objective was to quantify the variability in multiaxial test results among several laboratories. Only included is data which was generated at the NASA Lewis Research Center's High Temperature Fatigue and Structures Laboratory. The experimental equipment and procedures used are described. The tubular specimens were polished on the outer surface to aid in the use of a cellulose film surface replication technique for crack detection. However, cracking initiated predominantly on the internal surface for all specimens. Honing of the bore of the tubular specimens lessened but did not entirely eliminate this problem. The observed fatigue lives are compared with lives calculated from three multiaxial life models. Constants for the life prediction models were obtained from uniaxial and torsional tests performed on the same heat of material. The observed fatigue lives agreed with calculated lives to within a factor of two for all but one of the life prediction models.
Bonacuse, Peter J.↗
Automation software for a materials testing laboratory
A comprehensive software system for automating much of the experimental process has recently been completed at the Lewis Research Center's high-temperature fatigue and structures laboratory. The system was designed to support experiment definition and conduct, results analysis and archiving, and report generation activities. This was accomplished through the design and construction of several software systems, as well as through the use of several commercially available software products, all operating on a local, distributed minicomputer system. Experimental capabilities currently supported in an automated fashion include both isothermal and thermomechanical fatigue and deformation testing capabilities. The future growth and expansion of this system will be directed toward providing multiaxial test control, enhanced thermomechanical test control, and higher test frequency (hundreds of hertz).
Mcgaw, Michael A.↗
Creep fatigue life prediction for engine hot section materials (isotropic)
The first two years of a two-phase program aimed at improving the high temperature crack initiation life prediction technology for gas turbine hot section components are discussed. In Phase 1 (baseline) effort, low cycle fatigue (LCF) models, using a data base generated for a cast nickel base gas turbine hot section alloy (B1900+Hf), were evaluated for their ability to predict the crack initiation life for relevant creep-fatigue loading conditions and to define data required for determination of model constants. The variables included strain range and rate, mean strain, strain hold times and temperature. None of the models predicted all of the life trends within reasonable data requirements. A Cycle Damage Accumulation (CDA) was therefore developed which follows an exhaustion of material ductility approach. Material ductility is estimated based on observed similarities of deformation structure between fatigue, tensile and creep tests. The cycle damage function is based on total strain range, maximum stress and stress amplitude and includes both time independent and time dependent components. The CDA model accurately predicts all of the trends in creep-fatigue life with loading conditions. In addition, all of the CDA model constants are determinable from rapid cycle, fully reversed fatigue tests and monotonic tensile and/or creep data.
Moreno, Vito↗
Design of the advanced regional aircraft, the DART-75
The need for regional aircraft stems from the problem of hub airport congestion. Regional travel will allow a passenger to commute from one spoke city to another spoke city without entering the congested hub airport. In addition, those people traveling longer routes may begin the flight at home instead of traveling to the hub airport. At this time, there is no American aerospace company that produces a regional transport for under 100 passengers. The intention of the Developmental Advanced Regional Transport (DART-75) is to fill this void with a modern, efficient regional aircraft. This design achieves the efficiency through a number of advanced features including three lifting surfaces, partial composite construction, and an advanced engine design. Efficiency is not the only consideration. Structural integrity, fatigue life, ease of maintenance, passenger comfort and convenience, and environmental aspects must all be considered. These factors force the design team to face many tradeoffs that are studied to find the best solution. The final consideration that cannot be overlooked is that of cost. The DART-75 is a 75-passenger medium-range regional transport intended for spoke-to-spoke, spoke-to-hub, and some hub-to-hub operations. Included are the general descriptions of the structures, weight and balance, stability and control, performance, and engine design.
Elliot, Steve↗
A Novel Approach to Rotorcraft Damage Tolerance
Damage-tolerance methodology is positioned to replace safe-life methodologies for designing rotorcraft structures. The argument for implementing a damage-tolerance method comes from the fundamental fact that rotorcraft structures typically fail by fatigue cracking. Therefore, if technology permits prediction of fatigue-crack growth in structures, a damage-tolerance method should deliver the most accurate prediction of component life. Implementing damage-tolerance (DT) into high-cycle-fatigue (HCF) components will require a shift from traditional DT methods that rely on detecting an initial flaw with nondestructive inspection (NDI) methods. The rapid accumulation of cycles in a HCF component will result in a design based on a traditional DT method that is either impractical because of frequent inspections, or because the design will be too heavy to operate efficiently. Furthermore, once a HCF component develops a detectable propagating crack, the remaining fatigue life is short, sometimes less than one flight hour, which does not leave sufficient time for inspection. Therefore, designing a HCF component will require basing the life analysis on an initial flaw that is undetectable with current NDI technology.
Forth, Scott C.↗
Aircraft fatigue and crack growth considering loads by structural component
The indisputable 1968 C-130 fatigue/crack growth data is reviewed to obtain additional useful information on fatigue and crack growth. The proven Load Environment Model concept derived empirically from F-105D multichannel recorder data is refined to a simpler method by going from 8 to 5 variables in the spectra without a decrease in accuracy. This approach provides the true fatigue/crack growth and load environment by structural component for both fatigue and strength design. Methods are presented for defining fatigue scatter and damage at crack initiation. These design tools and criteria may be used for both metal and composite aircraft structure.
Yost, J. D.↗