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Objectives of study were: investigation of temperature changes caused by welding arc with analysis of temperature distribution; development of system of mathematical statements describing thermal stresses and plastic strains during welding; and development of system of mathematical solutions and computer programs for one-dimensional analysis.
The method is for metallic matrix composites, such as laminated sheet or foil composites. Non-intersecting discrete discontinuities are positively introduced into the interface between the layers so as to reduce the thermal stress produced by unequal expansion of the materials making up the composite. The discontinuities are preferably produced by drilling holes in the metallic matrix layer. However, a plurality of discrete elements may be used between the layers to carry out this purpose.
A method is provided for alleviating the stress damage in metallic matrix composites, such as laminated sheet or foil composites. Discontinuities are positively introduced into the interface between the layers so as to reduce the thermal stress produced by unequal expansion of the materials making up the composite. Although a number of discrete elements could be used to form one of the layers and thus carry out this purpose, the discontinuities are preferably produced by simply drilling holes in the metallic matrix layer or by forming grooves in a grid pattern in this layer.
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.
An approach for predicting remaining useful life of power MOSFETs (metal oxide field effect transistor) devices has been developed. Power MOSFETs are semiconductor switching devices that are instrumental in electronics equipment such as those used in operation and control of modern aircraft and spacecraft. The MOSFETs examined here were aged under thermal overstress in a controlled experiment and continuous performance degradation data were collected from the accelerated aging experiment. Dieattach degradation was determined to be the primary failure mode. The collected run-to-failure data were analyzed and it was revealed that ON-state resistance increased as die-attach degraded under high thermal stresses. Results from finite element simulation analysis support the observations from the experimental data. Data-driven and model based prognostics algorithms were investigated where ON-state resistance was used as the primary precursor of failure feature. A Gaussian process regression algorithm was explored as an example for a data-driven technique and an extended Kalman filter and a particle filter were used as examples for model-based techniques. Both methods were able to provide valid results. Prognostic performance metrics were employed to evaluate and compare the algorithms.
Rayleigh-Ritz and modified Rayleigh-Ritz procedures are used to construct approximate solutions for the response of a thick-walled sphere to uniform pressure loads and an arbitrary radial temperature distribution. The thermoelastic properties of the sphere are assumed to be transversely isotropic and nonhomogeneous; variations in the elastic stiffness and thermal expansion coefficients are taken to be an arbitrary function of the radial coordinate and temperature. Numerical examples are presented which illustrate the effect of the temperature-dependence upon the thermal stress field. A comparison of the approximate solutions with a finite element analysis indicates that Ritz methods offer a simple, efficient, and relatively accurate approach to the problem.
A test structure representing a portion of a hypersonic vehicle was instrumented with strain gages and thermocouples. This test structure was then subjected to laboratory heating representative of supersonic and hypersonic flight conditions. A finite element computer model of this structure was developed using several types of elements with the NASA structural analysis (NASTRAN) computer program. Temperature inputs from the test were used to generate predicted model thermal stresses and these were correlated with the test measurements.
This paper presents results from a finite element micromechanics analysis of thermally induced stresses in composites at cryogenic temperatures typical of spacecraft operating environments. The influence of microstructural geometry, constituent and interphase properties, and laminate orientation were investigated. Stress field results indicated that significant matrix stresses occur in composites exposed to typical spacecraft thermal excursions; these stresses varied with laminate orientation and circumferential position around the fiber. The major difference in the predicted response of unidirectional and multidirectional laminates was the presence of tensile radial stresses, at the fiber/matrix interface, in multidirectional laminates with off-axis ply angles greater than 15 deg. The predicted damage initiation temperatures and modes were in good agreement with experimental data for both low (207 GPa) and high (517 GPa) modulus carbon fiber/epoxy composites.
A nuclear reactor vessel is supported by a Z-ring and a box ring girder. The two proposed structural configurations to transmit the loads from the Z-ring and the box ring girder to the foundation are shown. The cantilever concrete ledge transmitting the load from the Z-ring and the box girder via the cavity wall to the foundation is shown, along with the loads being transmitted through one of the six steel columns. Both of these two supporting systems were analyzed by using rigid format 9 of NASTRAN for dynamic loads, and the thermal stresses were analyzed by AXISOL. The six column configuration was modeled by a combination of plate and bar elements, and the concrete cantilever ledge configuration was modeled by plate elements. Both configurations were found structurally satisfactory; however, nonstructural considerations favored the concrete cantilever ledge.
The fundamentals of the thermodynamic theory of mixtures and continuum thermochemistry are reviewed for a mixture of condensed water and polymer. A specific mixture which is mechanically elastic with temperature and water concentration gradients present is considered. An expression for the partial pressure of water in the mixture is obtained based on certain assumptions regarding the thermodynamic state of the water in the mixture. Along with a simple diffusion equation, this partial pressure expression may be used to simulate the thermostructural behavior of polymer composite materials due to water in the free volumes of the polymer. These equations are applied to a specific polymer composite material during isothermal heating conditions. The thermal stresses obtained by the application of the theory are compared to measured results to verify the accuracy of the approach.
This paper summarizes work to determine the thermally-induced stresses and deformations in specially-constructed angle-ply composite tubes subjected to a uniform temperature change relative to their stress-free cure state. The tubes are designed for application to space structures and have high axial stiffness. Four angle-ply designs are examined in an effort to determine which design might have the most favorable thermally-induced response. A planar elasticity solution is used, the solution being valid away from the ends of the tube. Of the four designs considered, none has any particular advantage as far as stress levels are concerned. However, despite the fact that the tube wall is a balanced laminate, one design exhibits a significant amount of thermally-induced twist.
High-temperature thin-shell leading-edge buckling test data are analyzed using NASA structural analysis (NASTRAN) as a finite element tool for predicting thermal buckling characteristics. Buckling points are predicted for several combinations of edge boundary conditions. The problem of relating the appropriate plate area to the edge stress distribution and the stress gradient is addressed in terms of analysis assumptions. Local plasticity was found to occur on the specimen analyzed, and this tended to simplify the basic problem since it effectively equalized the stress gradient from loaded edge to loaded edge. The initial loading was found to be difficult to select for the buckling analysis because of the transient nature of thermal stress. Multiple initial model loadings are likely required for complicated thermal stress time histories before a pertinent finite element buckling analysis can be achieved. The basic mode shapes determined from experimentation were correctly identified from computation.
The paper discusses how features of the surface geology of the moon and also Mars and Mercury impose constraints on the volumetric expansion or contraction of a planet and consequently provide a test of thermal history models. The moon has changed very little in volume over the last 3.8 b.y. Thermal models satisfying this constraint involve early heating and perhaps melting of the outer 200 km of the moon and an initially cold interior. Mercury has contracted by about 2 km in radius since emplacement of its present surface, so core formation must predate that surface. A hot initial temperature distribution is implied.
This paper addresses the computation of thermally induced stresses in layered, fiber-reinforced composite tubes subjected to a circumferential gradient. The paper focuses on using the principle of complementary virtual work, in conjunction with a Ritz approximation to the stress field, to study the influence on the predicted stresses of including temperature-dependent material properties. Results indicate that the computed values of stress are sensitive to the temperature dependence of the matrix-direction compliance and matrix-direction thermal expansion in the plane of the lamina. There is less sensitivity to the temperature dependence of the other material properties.
A micromechanics analysis is used to study the effects of constituent properties on thermally induced stresses in continuous fiber reinforced composites. A finite element formulation is described, and results are presented for unidirectional carbon/epoxy laminates. It is shown that significant stresses develop in composites exposed to thermal excursions typical of spacecraft operating environments and that the fiber thermoelastic properties have a minimal effect on the magnitude of these stresses. The finite element micromechanics analysis is then extended to the study of multidirectional laminates using a simple global/local formulation. Damage initiation predictions are compared with experimental data, and factors controlling the initiation of damage are identified. Ways of improving the durability of composites are discussed.
A thermal cycling experiment was performed on GaAs solar cells to establish the electrical and structural integrity of these cells under the temperature conditions of a simulated low-Earth orbit of 3-year duration. Thirty single junction GaAs cells were obtained and tests were performed to establish the beginning-of-life characteristics of these cells. The tests consisted of cell I-V power output curves, from which were obtained short-circuit current, open circuit voltage, fill factor, and cell efficiency, and optical micrographs, spectral response, and ion microprobe mass analysis (IMMA) depth profiles on both the front surfaces and the front metallic contacts of the cells. Following 5,000 thermal cycles, the performance of the cells was reexamined in addition to any factors which might contribute to performance degradation. It is established that, after 5,000 thermal cycles, the cells retain their power output with no loss of structural integrity or change in physical appearance.
Rock boulders are considerably typical of airless rocky bodies throughout the inner solar system, so their environments prove useful to understanding the rates of surface-modification processes and “survival times” of these boulders. On the Moon, there are meter-sized boulders on the rims of small lunar carters of some known age, so modeling the rock destruction is applied. Interior and exterior stresses must be considered, including thermal day-night cycling of the regolith and sub-regolith, and solar wind.
The prognostic technique for a power MOSFET presented in this paper is based on accelerated aging of MOSFET IRF520Npbf in a TO-220 package. The methodology utilizes thermal and power cycling to accelerate the life of the devices. The major failure mechanism for the stress conditions is dieattachment degradation, typical for discrete devices with leadfree solder die attachment. It has been determined that dieattach degradation results in an increase in ON-state resistance due to its dependence on junction temperature. Increasing resistance, thus, can be used as a precursor of failure for the die-attach failure mechanism under thermal stress. A feature based on normalized ON-resistance is computed from in-situ measurements of the electro-thermal response. An Extended Kalman filter is used as a model-based prognostics techniques based on the Bayesian tracking framework. The proposed prognostics technique reports on preliminary work that serves as a case study on the prediction of remaining life of power MOSFETs and builds upon the work presented in [1]. The algorithm considered in this study had been used as prognostics algorithm in different applications and is regarded as suitable candidate for component level prognostics. This work attempts to further the validation of such algorithm by presenting it with real degradation data including measurements from real sensors, which include all the complications (noise, bias, etc.) that are regularly not captured on simulated degradation data. The algorithm is developed and tested on the accelerated aging test timescale. In real world operation, the timescale of the degradation process and therefore the RUL predictions will be considerable larger. It is hypothesized that even though the timescale will be larger, it remains constant through the degradation process and the algorithm and model would still apply under the slower degradation process. By using accelerated aging data with actual device measurements and real sensors (no simulated behavior), we are attempting to assess how such algorithm behaves under realistic conditions.