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At least 163 records · Page 9

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NASA NTRS1997

Influence of High Cycle Thermal Loads on Thermal Fatigue Behavior of Thick Thermal Barrier Coatings

Thick thermal barrier coating systems in a diesel engine experience severe thermal Low Cycle Fatigue (LCF) and High Cycle Fatigue (HCF) during engine operation. In the present study, the mechanisms of fatigue crack initiation and propagation, as well as of coating failure, under thermal loads which simulate engine conditions, are investigated using a high power CO2 laser. In general, surface vertical cracks initiate early and grow continuously under LCF and HCF cyclic stresses. It is found that in the absence of interfacial oxidation, the failure associated with LCF is closely related to coating sintering and creep at high temperatures, which induce tensile stresses in the coating after cooling. Experiments show that the HCF cycles are very damaging to the coating systems. The combined LCF and HCF tests produced more severe coating surface cracking, microspallation and accelerated crack growth, as compared to the pure LCF test. It is suggested that the HCF component cannot only accelerate the surface crack initiation, but also interact with the LCF by contributing to the crack growth at high temperatures. The increased LCF stress intensity at the crack tip due to the HCF component enhances the subsequent LCF crack growth. Conversely, since a faster HCF crack growth rate will be expected with lower effective compressive stresses in the coating, the LCF cycles also facilitate the HCF crack growth at high temperatures by stress relaxation process. A surface wedging model has been proposed to account for the HCF crack growth in the coating system. This mechanism predicts that HCF damage effect increases with increasing temperature swing, the thermal expansion coefficient and the elastic modulus of the ceramic coating, as well as the HCF interacting depth. A good agreement has been found between the analysis and experimental evidence.

Zhu, Dongming↗

NASA NTRS1981

Dynamic tensile strength of lunar rock types

The dynamic tensile strength of four rocks are determined. A flat plate impact experiment is employed to generate approximately one-microsecond-duration tensile stress pulses in rock samples by superposing rarefaction waves to induce fracture. It is noted that the effect of chemical weathering and other factors has not been explicitly studied. The given tensile strengths are based on a series of experiments on each rock where determination of incipient spallation is made by terminal microscopic examination. The data are generally consistent with previous determinations, at least one of which was for a significantly chemically altered but physically coherent rock.

Cohn, S. N.↗

NASA NTRS2017

Stress Compensating Multilayers

We present in-situ stress measurement results for single and multilayer thin-films deposited by magnetron sputtering. In particular, we report on the influence of the material interfaces on the ensuing stress in both the transient and steady-state regimes of film growth. This behavior is used to determine the appropriate thicknesses of the constituent layers that will result in a net tensile stress in multilayers composed of various material combinations. These multilayers can then be used to compensate the compressive integrated stress in single and multilayer EUV and x-ray optical coatings. The use of multilayers to compensate the integrated stress might be advantageous because, unlike single layers of chromium, the roughness is not expected to increase with the total thickness of the multilayer. In this paper, we demonstrate the technique for W/Si and Mo/Si multilayers and discuss its application to other material combinations.

Multilayer↗

NASA NTRS1983

An investigation of the accuracy of finite difference methods in the solution of linear elasticity problems

The accuracy of the finite difference method in the solution of linear elasticity problems that involve either a stress discontinuity or a stress singularity is considered. Solutions to three elasticity problems are discussed in detail: a semi-infinite plane subjected to a uniform load over a portion of its boundary; a bimetallic plate under uniform tensile stress; and a long, midplane symmetric, fiber reinforced laminate subjected to uniform axial strain. Finite difference solutions to the three problems are compared with finite element solutions to corresponding problems. For the first problem a comparison with the exact solution is also made. The finite difference formulations for the three problems are based on second order finite difference formulas that provide for variable spacings in two perpendicular directions. Forward and backward difference formulas are used near boundaries where their use eliminates the need for fictitious grid points.

Bauld, N. R., Jr.↗

NASA NTRS1995

Bend stress relaxation and tensile primary creep of a polycrystalline alpha-SiC fiber

Understanding the thermomechanical behavior (creep and stress relaxation) of ceramic fibers is of both practical and basic interest. On the practical level, ceramic fibers are the reinforcement for ceramic matrix composites which are being developed for use in high temperature applications. It is important to understand and model the total creep of fibers at low strain levels where creep is predominantly in the primary stage. In addition, there are many applications where the component will only be subjected to thermal strains. Therefore, the stress relaxation of composite consituents in such circumstances will be an important factor in composite design and performance. The objective of this paper is to compare and analyze bend stress relaxation and tensile creep data for alpha-SiC fibers produced by the Carborundum Co. (Niagara Falls, NY). This fiber is of current technical interest and is similar in composition to bulk alpha-SiC which has been studied under compressive creep conditions. The temperature, time, and stress dependences will be discussed for the stress relaxation and creep results. In addition, some creep and relaxation recovery experiments were performed in order to understand the complete viscoelastic behavior, i.e. both recoverable and nonrecoverable creep components of these materials. The data will be presented in order to model the deformation behavior and compare relaxation and/or creep behavior for relatively low deformation strain conditions of practical concern. Where applicable, the tensile creep results will be compared to bend stress relaxation data.

Hee Man, Yun↗

NASA NTRS1977

Thermal stress analysis of a graded zirconia/metal gas path seal system for aircraft gas turbine engines

A ceramic/metallic aircraft gas turbine outer gas path seal designed to enable improved engine performance is studied. Flexible numerical analysis schemes suitable for the determination of transient temperature profiles and thermal stress distributions in the seal are outlined. An estimation of the stresses to which a test seal is subjected during simulated engine deceleration from sea level takeoff to idle conditions is made. Experimental evidence has indicated that the surface layer of the seal is probably subjected to excessive tensile stresses during cyclic temperature loading. This assertion is supported by the analytical results presented. Brief consideration is given to means of mitigating this adverse stressing.

Taylor, C. M.↗

NASA NTRS1996

RAINBOWS and CERAMBOWS: The Technologies of Pre-Stressed Piezo Actuators

Amplified mechanical displacement effects, similar to those observed in the recently reported Rainbow actuators, have also been found to exist in prestressed ceramic/metal composite structures coined as CERAMBOW's - an acronym for CERamic And Metal Biased Oxide Wafer. Mimicking the Rainbows in many ways, the intentionally created internal compressive and tensile stresses within the Cerambows are used to amplify their displacement properties via the combined effects of piezoelectric d31 strain and domain reorientation. They are fabricated from ferroelectric, piezoelectric or electrostrictive materials and metal substrates of significantly different thermal expansions which are largely responsible for the creation of the stress. Typical ceramics used in Cerambows are PZT, PLZT, PBZT, PSZT and PMN and some typical metal substrates are Al, Ag, Ni, brass, steel and Be/Cu foil. Shapes can vary from round disks to square plates and rectangular bars. Formed at an elevated temperature of approximately 250 C, the stresses on cooling to room temperature are generally sufficient to produce displacements as large as 0.125mm (5 mils) when activated unipolar and 0.25mm (10 mils) when operated bipolar at 450 volts in a dome mode. Comparing equal structures of a Cerambow with a Rainbow, the Cerambow was found to achieve approximately 70% of the displacement that would normally be obtained with a Rainbow. Although this difference in displacement is sufficient to prefer a Rainbow for many applications, there are some advantages for the Cerambow. Among these are (1) the processing temperatures are lower, (2) high lead-containing ceramics are not required and (3) in some instances the metal substrate is more convenient to interface with other elements of a device. However, the disadvantages include (1) lower displacement in the dome mode of operation, (2) the higher displacement saddle mode has not yet been demonstrated with a Cerambow and (3) the ceramic/metal bond interface is a possible failure area when operated for extended periods of time. The applications for Cerambows are considered to be similar to Rainbows, i.e., actuators, pumps, deflectors, vibrators, speakers, hydrophones, hydroprojectors, switches, etc.

Haertling, Gene H.↗

NASA NTRS1995

Active Control of Fan Noise-Feasibility Study. Volume 2: Canceling Noise Source-Design of an Acoustic Plate Radiator Using Piezoceramic Actuators

The feasibility of using acoustic plate radiators powered by piezoceramic thin sheets as canceling sources for active control of aircraft engine fan noise is demonstrated. Analytical and numerical models of actuated beams and plates are developed and validated. An optimization study is performed to identify the optimum combination of design parameters that maximizes the plate volume velocity for a given resonance frequency. Fifteen plates with various plate and actuator sizes, thicknesses, and bonding layers were fabricated and tested using results from the optimization study. A maximum equivalent piston displacement of 0.39 mm was achieved with the optimized plate samples tested with only one actuator powered, corresponding to a plate deflection at the center of over 1 millimeter. This is very close to the deflection required for a full size engine application and represents a 160-fold improvement over previous work. Experimental results further show that performance is limited by the critical stress of the piezoceramic actuator and bonding layer rather than by the maximum moment available from the actuator. Design enhancements are described in detail that will lead to a flight-worthy acoustic plate radiator by minimizing actuator tensile stresses and reducing nonlinear effects. Finally, several adaptive tuning methods designed to increase the bandwidth of acoustic plate radiators are analyzed including passive, active, and semi-active approaches. The back chamber pressurization and volume variation methods are investigated experimentally and shown to be simple and effective ways to obtain substantial control over the resonance frequency of a plate radiator. This study shows that piezoceramic-based plate radiators can be a viable acoustic source for active control of aircraft engine fan noise.

Pla, F. G.↗

NASA NTRS1976

Effective defect density for MOS breakdown - Dependence on oxide thickness

A new procedure for measuring effective defect density takes time-dependent primary dielectric breakdown in MOS devices into account. A time-varying breakdown probability is obtained by applying a constant field stress to a statistically sufficient number of MOS capacitors. Effective defects are assumed distributed randomly in two dimensions, hence indistinguishable. The effective defect density is found to vary with oxide thickness; tentative explanations are ventured to account for this (interfacial tensile stress, ion patching enhanced by local trapping, breakdown in the form of filamentary discharges with release of stored electrostatic energy).

Li, S. P.↗

NASA NTRS2003

Hydrostatic Stress Effect on the Yield Behavior of Inconel 100

Classical metal plasticity theory assumes that hydrostatic stress has negligible effect on the yield and postyield behavior of metals. Recent reexaminations of classical theory have revealed a significant effect of hydrostatic stress on the yield behavior of various geometries. Fatigue tests and nonlinear finite element analyses (FEA) of Inconel 100 (IN100) equal-arm bend specimens and new monotonic tests and nonlinear finite element analyses of IN100 smooth tension, smooth compression, and double-edge notch tension (DENT) test specimens have revealed the effect of internal hydrostatic tensile stresses on yielding. Nonlinear FEA using the von Mises (yielding is independent of hydrostatic stress) and the Drucker-Prager (yielding is linearly dependent on hydrostatic stress) yield functions were performed. A new FEA constitutive model was developed that incorporates a pressure-dependent yield function with combined multilinear kinematic and multilinear isotropic hardening using the ABAQUS user subroutine (UMAT) utility. In all monotonic tensile test cases, the von Mises constitutive model, overestimated the load for a given displacement or strain. Considering the failure displacements or strains for the DENT specimen, the Drucker-Prager FEM s predicted loads that were approximately 3% lower than the von Mises values. For the failure loads, the Drucker Prager FEM s predicted strains that were up to 35% greater than the von Mises values. Both the Drucker-Prager model and the von Mises model performed equally-well in simulating the equal-arm bend fatigue test.

Allen, Phillip A.↗

NASA NTRS2002

Hydrostatic Stress Effect On the Yield Behavior of Inconel 100

Classical metal plasticity theory assumes that hydrostatic stress has no effect on the yield and postyield behavior of metals. Recent reexaminations of classical theory have revealed a significant effect of hydrostatic stress on the yield behavior of notched geometries. New experiments and nonlinear finite element analyses (FEA) of Inconel 100 (IN 100) equal-arm bend and double-edge notch tension (DENT) test specimens have revealed the effect of internal hydrostatic tensile stresses on yielding. Nonlinear FEA using the von Mises (yielding is independent of hydrostatic stress) and the Drucker-Prager (yielding is linearly dependent on hydrostatic stress) yield functions was performed. In all test cases, the von Mises constitutive model, which is independent of hydrostatic pressure, overestimated the load for a given displacement or strain. Considering the failure displacements or strains, the Drucker-Prager FEMs predicted loads that were 3% to 5% lower than the von Mises values. For the failure loads, the Drucker Prager FEMs predicted strains that were 20% to 35% greater than the von Mises values. The Drucker-Prager yield function seems to more accurately predict the overall specimen response of geometries with significant internal hydrostatic stress influence.

Allen, Phillip A.↗

NASA NTRS1978

Temperature distributions and thermal stresses in a graded zirconia/metal gas path seal system for aircraft gas turbine engines

A ceramic/metallic aircraft gas turbine outer gas path seal designed for improved engine performance was studied. Transient temperature and stress profiles in a test seal geometry were determined by numerical analysis. During a simulated engine deceleration cycle from sea-level takeoff to idle conditions, the maximum seal temperature occurred below the seal surface, therefore the top layer of the seal was probably subjected to tensile stresses exceeding the modulus of rupture. In the stress analysis both two- and three-dimensional finite element computer programs were used. Predicted trends of the simpler and more easily usable two-dimensional element programs were borne out by the three-dimensional finite element program results.

Taylor, C. M.↗

NASA NTRS1991

Effect of interlaminar normal stresses on the uniaxial zero-to-tension fatigue behavior of graphite/epoxy tubes

Fatigue tests conducted with and without internal pressure have been found to possess approximately the same fatigue life as (+/-45)s graphite/epoxy tubes for zero-to-tension axial load-controlled conditions on an axial torsion servohydraulic apparatus. These tests therefore cannot be considered as confirmations of the suspected detrimental effect of interlaminar tensile stresses on the fatigue performance of thin-walled tubes. The addition of 90-deg plies on both the inside and the outside is found to significantly improve the tubes' static and fatigue strengths.

Krempl, Erhard↗

NASA NTRS1985

SCARE: A post-processor program to MSC/NASTRAN for the reliability analysis of structural ceramic components

A computer program was developed for calculating the statistical fast fracture reliability and failure probability of ceramic components. The program includes the two-parameter Weibull material fracture strength distribution model, using the principle of independent action for polyaxial stress states and Batdorf's shear-sensitive as well as shear-insensitive crack theories, all for volume distributed flaws in macroscopically isotropic solids. Both penny-shaped cracks and Griffith cracks are included in the Batdorf shear-sensitive crack response calculations, using Griffith's maximum tensile stress or critical coplanar strain energy release rate criteria to predict mixed mode fracture. Weibull material parameters can also be calculated from modulus of rupture bar tests, using the least squares method with known specimen geometry and fracture data. The reliability prediction analysis uses MSC/NASTRAN stress, temperature and volume output, obtained from the use of three-dimensional, quadratic, isoparametric, or axisymmetric finite elements. The statistical fast fracture theories employed, along with selected input and output formats and options, are summarized. An example problem to demonstrate various features of the program is included.

Gyekenyesi, J. P.↗

NASA NTRS1986

SCARE - A postprocessor program to MSC/NASTRAN for reliability analysis of structural ceramic components

Gyekenyesi, J. P.↗

NASA NTRS2018

Electrical Properties of Unidirectional Carbon Fiber Reinforced Epoxy-Graphene Composites

This paper aims at establishing connections between electrical resistivity and stresses in carbon fiber reinforced epoxy-graphene composites. To avoid the interconnection of multiple parameters, we examined composite specimens consisting of a single strand or tow (12,000 carbon fiber filaments) embedded in an epoxy matrix containing up to 1.0 wt% of graphene (TG679) particles. The specimens show resistance increase with the tensile stress. The characteristic of the dependence varies with the content of graphene particles, tending to be linear as the percentage of graphene content increases. We did not observe any significant changes in the ultimate strength of the composite with an increase of the graphene particles concentration.

Daniel Wentzel↗

NASA NTRS1991

Dynamic tensile-failure-induced velocity deficits in rock

Planar impact experiments were employed to induce dynamic tensile failure in Bedford limestone. Rock disks were impacted with aluminum and polymethyl methacralate (PMMA) flyer plates at velocities of 10 to 25 m/s. Tensile stress magnitudes and duration were chosen so as to induce a range of microcrack growth insufficient to cause complete spalling of the samples. Ultrasonic P- and S-wave velocities of recovered targets were compared to the velocities prior to impact. Velocity reduction, and by inference microcrack production, occurred in samples subjected to stresses above 35 MPa in the 1.3 microsec PMMA experiments and 60 MPa in the 0.5 microsec aluminum experiments. Using a simple model for the time-dependent stress-intensity factor at the tips of existing flaws, apparent fracture toughnesses of 2.4 and 2.5 MPa sq rt m are computed for the 1.3 and 0.5 microsec experiments. These are a factor of about 2 to 3 greater than quasi-static values. The greater dynamic fracture toughness observed may result from microcrack interaction during tensile failure. Data for water-saturated and dry targets are indistinguishable.

Rubin, Allan M.↗

NASA NTRS2004

Coating Development for GRCop-84 Liners for Reusable Launch Vehicles Aided by Modeling Studies

The design of the next generation of reusable launch vehicles calls for using GRCop-84 copper alloy liners based on a composition invented at the NASA Glenn Research Center. Despite its considerable advantage over other copper alloys, it is expected that GRCop-84 will suffer from environmental degradation depending on the type of rocket fuels used and on thermomechanical fatigue. Applying protective coatings on GRCop-84 substrates can minimize or eliminate many of these problems and extend the operational life of the combustion liner. This could increase component reliability, shorten depot maintenance turnaround times, and lower operating costs. Therefore, Glenn is actively pursuing the development of advanced coatings technology for GRCop-84 liners. Technology is being developed in four major areas: (1) new metallic coating compositions, (2) application techniques, (3) test methods, and (4) life prediction design methodology using finite element analysis. The role of finite element analysis in guiding the coating effort is discussed in this report. Thermal analyses were performed at Glenn for different combinations of top- and bondcoat compositions to determine the temperature variation across the coated cross section with the thickness of the top coat. These calculations were conducted for simulated LH2/LO2 booster engine conditions assuming that the bond coat had a constant thickness of 50 m. The preceding graphs show the predicted temperatures at the outer surface of the top coat (hot wall), at the top-coat/bond-coat interface, at the bond-coat/GRCop-84 interface, and at the GRCop-84 cold wall as a function of top-coat thickness for Cu- 26(wt%)Cr top coat (top graph), Ni-17(wt%)Cr-6%Al-0.5%Y top coat and Cu-26%Cr bond coat, and NiAl top coat and Ni bond coat. In all cases, the temperature of the top coat at the hot wall increased with increasing top-coat thickness and with corresponding decreases in the temperatures at the two interfaces and the cold wall. These temperatures are not acutely sensitive to the thermal conductivity of the top coat when it exceeds 25 and 50 W/m/K for low and high heat flux engines. This observation is significant for two reasons. First, several different top-coat compositions can be evaluated as potential protective coatings without loss in the heat-transfer efficiency of the coated system. Second, materials with thermal conductivities less than the critical values of 25 or 50 W/m/K are more likely to act as thermal barrier coatings. The deposition of overlay coatings on GRCop-84 substrates results in the development of residual stresses. The presence of these residual stresses influences the probability of coating spallation, the thermal cycling life, and the fatigue properties of the coated substrate during use. Since it is important to understand how these stresses develop during the vacuum-plasma-spraying coating deposition process, the nature and magnitudes of the cool-down residual stresses were calculated and compared with experimentally determined values across the coated cross section of a disk specimen. The calculations were conducted assuming that the specimen cools down to room temperature from vacuum plasma-spraying temperatures of either 250 or 650 C. The effects of coating the substrate with and without grit blasting were also theoretically examined. The final graph compares the predicted and the experimental results for a GRCop-84 disk coated with about a 50- m-thick Ni bond coat and a 75- to 100- m NiAl top coat, where the curves for NASA-2 assume the presence of a prior residual stress generated by grit blasting under conditions similar to the experimental situation. The predicted cool-down in-plane stresses were compressive in both the NiAl top coat and the Ni bond coat. They were also compressive in the substrate to a depth of about 0.25 mm from the Ni/GRCop-84 interface when the vacuum-plasma-spraying temperature was low. However, using a higher plasma spraying temperaturs likely to leave the substrate under a small tensile stress to counter the compressive stresses in the bond and top coats because of the relaxation of residual stresses generated in the substrate during the grit blasting of its surface prior to spraying. These results suggest that the NiAl and Ni coatings are unlikely to spall after spraying as confirmed by the microstructural observations shown in the following photomicrograph of an as-sprayed specimen. Finally, it is noted that the calculated and experimental results are not in complete agreement, which indicates that both the experimental and modeling techniques need further refinement.

Raj, Sai V.↗