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Fracture Mechanics Testing of Titanium 6AL-4V in LMP-103S Propellant

Propellant tank safe-life analysis is a spacecraft propulsion subsystem Launch Range processing requirement. The material property inputs for the safe-life analysis include the stress intensity factor for environment-assisted cracking (KEAC). The KEAC for titanium alloy Ti 6Al-4V in LMP-103S propellant was determined experimentally using an innovative test method following ASTM E1681, Standard Test Method for Determining Threshold Stress Intensity Factor for Environment-Assisted Cracking of Metallic Materials. This effort was a collaboration between NASA Goddard Space Flight Center and NASA Kennedy Space Center to expose the test specimens in the propellant, while loaded in the test fixtures, for 1000- hour (42 days) at 50°C. Two test rounds have been completed to date; 1) testing mechanically loaded specimens but without propellant and 2) testing mechanically loaded specimens wetted with LMP-103S propellant. The dry test was to evaluate the crack growth without exposure to the LMP-103S propellant, and further assess the un-wetted stress intensity factor for the full 1000-hour duration. The second round of testing included the propellant soak for the requisite 1000- hour at 50°C. Current results show that the threshold intensity factor for environment-assisted cracking (exposed to LMP103S) is 22.5 ksi√in for the bulk material and 36. 2 ksi√in for the weld material. A generic ‘candidate’ tank geometry and material thickness is developed for a damage tolerance of known surface cracks below the nondestructive inspection technique detection limit. Evaluations with and without the use of a threshold intensity factor for environment-assisted cracking is performed for the required 4x propellant tank service life using the software tool NASGRO. SP2024_00239

Green propulsion↗

NASA NTRS1983

Correlations Between Metallurgical Characterization Studies, Exploratory Mechanical Tests, and Continuum Mechanics Approaches to Constitutive Equations

Austenitic stainless steels, such as types 316 and 304, are widely used as pressure vessel materials in the temperature range of 425 to 650 C. Stainless steel specimens were tested to rupture at two different stress levels sigma and sigma 2 sigma 1 sigma 2) to establish the normal stain-time behavior. A subsequent test was performed in which the specimen was crept at the higher stress (sigma 1) to the beginning of the secondary stage of creep, presumed to be the strain/time conditions at which a steady state microstructure is developed, and then the stress was reduced to the lower level (sigma 2). The associated microstructure, and significance of this microstructure on the creep strain-hardening model for variable uniaxial loads were assesed and found to be consistent with the use of creep-recovery models at high stresses and temperatures and strain-hardening models at low stresses and tempertures.

Moteff, J.↗

NASA NTRS1991

Cryo-mechanical tests of Ames 24E2 IR-black coating

In addition to the ambient condition tape test, five mechanical tests of the IR-black coating, Ames 24E2, were performed at either liquid helium or liquid nitrogen temperatures. Tensile strain in the coating at liquid nitrogen temperature was measured up to values of 4E-3, both before and after the coating was cycled down to liquid helium temperature. When applied to an aluminum substrate which was then bent in liquid nitrogen, the aluminum substrate always failed (permanently deformed) well before the coating failed. Sinusoidal accelerations up to 45 Gs in liquid nitrogen and 25 Gs in liquid helium did not crack or otherwise visibly damage the coating. Both sinusoidal and random acceleration at about 90 K of a representative baffle vane structure, at frequencies from 10 to 2000 Hz and up to 15 Gs, did not damage the coating, even at the intersection of a baffle with the telescope tube. Thus on a macroscopic level, cryogenic cooling and various levels of acceleration and strain did not affect this coating. However, on a microscopic scale, some loose particles were found associated with several tests. Outgassing data are also given.

Smith, Sheldon M.↗

NASA NTRS1990

Cryo-mechanical tests of Ames 24E2 IR-black coating

In addition to the ambient condition tape test, five mechanical tests of the IR-black coating, Ames 24E2, were performed at either liquid helium or liquid nitrogen teperatures. Tensile strain in the coating at liquid nitrogen temperature was measured up to values of 4E-3, both before and after the coating was cycled down to liquid helium temperature. When applied to an aluminum substrate which was then bent in liquid nitrogen, the aluminum substrate always failed (permanently deformed) well before the coating failed. Sinusoidal accelerations up to 45 Gs in liquid nitrogen and 25 Gs in liquid helium did not crack or otherwise visibly damage the coating. Both sinusoidal and random acceleration at about 90 K of a representative baffle vane structure, at frequencies from 10 to 2000 Hz and up to 15 Gs, did not damage the coating, even at the intersection of a baffle with the telescope tube. Thus on a macroscopic level, cryogenic cooling and various levels of acceleration and strain did not affect this coating. However, on a microscopic scale, some loose particles were found associated with several tests. Outgassing data are also given

Smith, Sheldon M.↗

NASA NTRS2007

Apparent-Strain Correction for Combined Thermal and Mechanical Testing

Combined thermal and mechanical testing requires that the total strain be corrected for the coefficient of thermal expansion mismatch between the strain gage and the specimen or apparent strain when the temperature varies while a mechanical load is being applied. Collecting data for an apparent strain test becomes problematic as the specimen size increases. If the test specimen cannot be placed in a variable temperature test chamber to generate apparent strain data with no mechanical loads, coupons can be used to generate the required data. The coupons, however, must have the same strain gage type, coefficient of thermal expansion, and constraints as the specimen to be useful. Obtaining apparent-strain data at temperatures lower than -320 F is challenging due to the difficulty to maintain steady-state and uniform temperatures on a given specimen. Equations to correct for apparent strain in a real-time fashion and data from apparent-strain tests for composite and metallic specimens over a temperature range from -450 F to +250 F are presented in this paper. Three approaches to extrapolate apparent-strain data from -320 F to -430 F are presented and compared to the measured apparent-strain data. The first two approaches use a subset of the apparent-strain curves between -320 F and 100 F to extrapolate to -430 F, while the third approach extrapolates the apparent-strain curve over the temperature range of -320 F to +250 F to -430 F. The first two approaches are superior to the third approach but the use of either of the first two approaches is contingent upon the degree of non-linearity of the apparent-strain curve.

Johnson, Theodore F.↗

NASA NTRS1991

The MSFC space station/space operations mechanism test bed

The Space Station/Space Operations Mechanism Test Bed consists of the following: a hydraulically driven, computer controlled Six Degree-of-Freedom Motion System (6DOF); a six degree-of-freedom force and moment sensor; remote driving stations with computer generated or live TV graphics; and a parallel digital processor that performs calculations to support the real time simulation. The function of the Mechanism Test Bed is to test docking and berthing mechanisms for Space Station Freedom and other orbiting space vehicles in a real time, hardware-in-the-loop simulation environment. Typically, the docking and berthing mechanisms are composed of two mating components, one for each vehicle. In the facility, one component is attached to the motion system, while the other component is mounted to the force/moment sensor fixed in the support structure above the 6DOF. The six components of the contact forces/moments acting on the test article and its mating component are measured by the force/moment sensor.

Sutton, William G.↗

NASA NTRS1991

Layered Plating Specimens For Mechanical Tests

Layered specimens readily made in standard sizes for tensile and other tests of mechanical properties. Standard specimen of metal ordinarily difficult to plate to standard grip thickness or diameter made by augmentation with easier-to-plate material followed by machining to standard size and shape.

Thompson, Linda B.↗

NASA NTRS2003

Status on Mechanical Testing at NASA GSFC

This viewgraph presentation provides an overview of current mechanical testing performed on spacecraft materials and instruments at NASA Goddard Space Flight Center. Specific mechanical testing procedures discussed include: force measurements limiting for sine, random vibration and acoustic tests, base driven model surveys, hydraulic shakers, new sine burst method and non contact sensors.

Kaufman, Daniel↗

NASA NTRS1990

Mechanical testing of large cryogenic structures

The mechanical testing performed on the Cryogenic Limb Array Etalon Spectrometer (CLAES) instrument installed on the Upper Atmosphere Research Satellite is discussed. The CLAES determines temperatures and concentrations of stratospheric minor species as a function of altitude by measuring the atmospheric infrared emission spectra. CLAES is based on a telescope optical system and infrared spectrometer which are cooled with cryogens.

Newkirk, Roger↗

NASA NTRS2003

Results of Mechanical Testing for Pyroceram(tm) Glass-Ceramic

Mechanical testing for Pyroceram (trademark) 9606 glass-ceramic fabricated by Corning was conducted to determine mechanical properties of the material including slow crack growth.Valid testing was not achieved in tension, compression, and shear testing due to inappropriate test specimen configurations provided and primarily due to the existence of fortified layer( in tension).

Choi, Sung R.↗

NASA NTRS1991

Mechanism test bed. Flexible body model report

The Space Station Mechanism Test Bed is a six degree-of-freedom motion simulation facility used to evaluate docking and berthing hardware mechanisms. A generalized rigid body math model was developed which allowed the computation of vehicle relative motion in six DOF due to forces and moments from mechanism contact, attitude control systems, and gravity. No vehicle size limitations were imposed in the model. The equations of motion were based on Hill's equations for translational motion with respect to a nominal circular earth orbit and Newton-Euler equations for rotational motion. This rigid body model and supporting software were being refined.

Compton, Jimmy↗

NASA NTRS2002

Initial Mechanical Testing of Superalloy Lattice Block Structures Conducted

The first mechanical tests of superalloy lattice block structures produced promising results for this exciting new lightweight material system. The testing was performed in-house at NASA Glenn Research Center's Structural Benchmark Test Facility, where small subelement-sized compression and beam specimens were loaded to observe elastic and plastic behavior, component strength levels, and fatigue resistance for hundreds of thousands of load cycles. Current lattice block construction produces a flat panel composed of thin ligaments arranged in a three-dimensional triangulated trusslike structure. Investment casting of lattice block panels has been developed and greatly expands opportunities for using this unique architecture in today's high-performance structures. In addition, advances made in NASA's Ultra-Efficient Engine Technology Program have extended the lattice block concept to superalloy materials. After a series of casting iterations, the nickel-based superalloy Inconel 718 (IN 718, Inco Alloys International, Inc., Huntington, WV) was successfully cast into lattice block panels; this combination offers light weight combined with high strength, high stiffness, and elevated-temperature durability. For tests to evaluate casting quality and configuration merit, small structural compression and bend test specimens were machined from the 5- by 12- by 0.5-in. panels. Linear elastic finite element analyses were completed for several specimen layouts to predict material stresses and deflections under proposed test conditions. The structural specimens were then subjected to room-temperature static and cyclic loads in Glenn's Life Prediction Branch's material test machine. Surprisingly, the test results exceeded analytical predictions: plastic strains greater than 5 percent were obtained, and fatigue lives did not depreciate relative to the base material. These assets were due to the formation of plastic hinges and the redundancies inherent in lattice block construction, which were not considered in the simplified computer models. The fatigue testing proved the value of redundancies since specimen strength was maintained even after the fracture of one or two ligaments. This ongoing test program is planned to continue through high-temperature testing. Also scheduled for testing are IN 718 lattice block panels with integral face sheets, as well as specimens cast from a higher temperature alloy. The initial testing suggests the value of this technology for large panels under low and moderate pressure loadings and for high-risk, damage-tolerant structures. Potential aeropropulsion uses for lattice blocks include turbine-engine actuated panels, exhaust nozzle flaps, and side panel structures.

Krause, David L.↗

NASA NTRS2004

Hydraulic Apparatus for Mechanical Testing of Nuts

The figure depicts an apparatus for mechanical testing of nuts. In the original application for which the apparatus was developed, the nuts are of a frangible type designed for use with pyrotechnic devices in spacecraft applications in which there are requirements for rapid, one-time separations of structures that are bolted together. The apparatus can also be used to test nonfrangible nuts engaged without pyrotechnic devices. This apparatus was developed to replace prior testing systems that were extremely heavy and immobile and characterized by long setup times (of the order of an hour for each nut to be tested). This apparatus is mobile, and the setup for each test can now be completed in about five minutes. The apparatus can load a nut under test with a static axial force of as much as 6.8 x 10(exp 5) lb (3.0 MN) and a static moment of as much as 8.5 x 10(exp 4) lb in. (9.6 x 10(exp 3) N(raised dot)m) for a predetermined amount of time. In the case of a test of a frangible nut, the pyrotechnic devices can be exploded to break the nut while the load is applied, in which case the breakage of the nut relieves the load. The apparatus can be operated remotely for safety during an explosive test. The load-generating portion of the apparatus is driven by low-pressure compressed air; the remainder of the apparatus is driven by 110-Vac electricity. From its source, the compressed air is fed to the apparatus through a regulator and a manually operated valve. The regulated compressed air is fed to a pneumatically driven hydraulic pump, which pressurizes oil in a hydraulic cylinder, thereby causing a load to be applied via a hydraulic nut (not to be confused with the nut under test). During operation, the hydraulic pressure is correlated with the applied axial load, which is verified by use of a load cell. Prior to operation, one end of a test stud (which could be an ordinary threaded rod or bolt) is installed in the hydraulic nut. The other end of the test stud passes through a bearing plate; a load cell is slid onto that end, and then the nut to be tested is threaded onto that end and tightened until the nut and load cell press gently against the bearing plate.

Hinkel, Todd J.↗

NASA NTRS2013

Micro-Scale Mechanical Testing of Non-Woven Carbon Nanotube Sheets and Yarns

Non-woven carbon nanotube (CNT) sheets and yarns were tested using a novel micro-scale mechanical testing system. CNT sheets were observed to delaminate during uniaxial testing using an adbesive gripping method, resulting from a higher proportion of load bearing in the outer sheets versus internal sheets and an apparently low interlaminar shear strength. In response to this, a new spool-grip method was used to alleviate non-uniform through-thickness stresses, circumvent premature delamination, and allow the sheet material to sustain a 72% increase in measured tensile strength. Furthermore, tension tests of CNT yarns showed that the yarn-structure was approximaiely 7 times stronger than the sheet structure, owing to a higher degree of CNT alignment in the test direction.

Magargee, J.↗

NASA NTRS2007

Thermal-Mechanical Testing of Hypersonic Vehicle Structures

A viewgraph presentation describing thermal-mechanical tests on the structures of hypersonic vehicles is shown. The topics include: 1) U.S. Laboratories for Hot Structures Testing; 2) NASA Dryden Flight Loads Laboratory; 3) Hot Structures Test Programs; 4) Typical Sequence for Hot Structures Testing; 5) Current Hot Structures Testing; and 6) Concluding Remarks.

Hudson, Larry↗

NASA NTRS2023

Manufacturing and Mechanical Testing of TC1225/LM-PAEK and TC1200/PEEK Thermoplastic Composite Panels

Development of thermoplastic composites (TPCs) for aerospace structures is experiencing renewed enthusiasm attributed to the availability of rapid manufacturing technology, ease of joining through fusion welding processes, and the successful utilization of the material in flight critical structures. Semicrystalline thermoplastics such as polyether ether ketone (PEEK), polyether ketone ketone (PEKK), and polyphenylene sulfide (PPS) have been successfully demonstrated as thermoplastic skins, keel beams, and angle brackets for commercial aircraft. Composite specimens were fabricated from the Toray TC1225 and TC1200 unidirectional prepreg systems and tested to gain confidence with NASA in-house TPC processing as part of the Thermoplastics Development for Exploration Application (TDEA) project. TC1225 is a relatively new material system that uses T700GC fibers and low-melt polyaryl ether ketone (LM-PAEK) resin. TC1200 is the latest version of a material system that has been available for several decades with AS4 fibers and PEEK resin. Results for ultrasonic inspection, optical microscopy, acid digestion, and differential scanning calorimetry establish the quality of the panels. Mechanical test data for unnotched and notched laminate tension and compression as well as compression after impact provide data for equivalency assessment and support material selection in TDEA. Satisfactory equivalence of the TC1225 results and the National Center for Advanced Materials Performance (NCAMP) database was found. The results indicate high-quality manufacturing was achieved, and the resulting mechanical test data are in agreement with that in the literature.

Thermoplastic Composites↗

NASA NTRS2016

Mechanical Testing of MLCCs

Cracking of multilayer ceramic capacitors, MLCCs, remains a serious problem for space systems. This problem increases substantially for large size capacitors and in cases when manual soldering is involved or the system experiences mechanical shock or vibration. In any case, a fracture occurs when the sum of external and internal mechanical stresses exceeds the strength of the part. To reduce the probability of cracking, the level of stress should be reduced, e.g. by optimizing the assembly workmanship and rules for board design, and the strength of the parts increased by selecting the most mechanically robust capacitors. The latter might possibly be achieved by selecting MLCCs based on the in-situ measurements of mechanical characteristics using four types of tests: flexural strength, hardness, fracture toughness, and flex bend testing. Note that military specifications MIL-PRF-123 and MIL-PRF-55681 do not have requirements for mechanical testing of the parts. However, specifications for automotive industry components employ two types of mechanical tests: beam load (break strength) test per AEC-Q200-003 and board flex test per AEC-Q200-005. A recent military specification for thin dielectric capacitors, MIL-PRF-32535, has one mechanical test, board flex testing, that is similar to AEC-Q200-005. The purpose of this report was assessment of the efficiency of different mechanical tests for selection robust capacitors and comparison of mechanical characteristics of Base Metal Electrode (BME) and Precious Metal Electrode (PME) capacitors. The report has three parts related to the first three mechanical tests mentioned above.

Precious Metal Electrode (PME) capacitors↗

NASA NTRS1985

Mechanical testing of large thallium doped sodium iodide single crystals

The findings of mechanical tests performed on five thallium-doped sodium iodide NaI(Tl) crystals are presented. These crystals are all in the shape of circular flat plates, 20.0 in. in diameter an d0.5 in. thick. The test setup, testing procedure, and the test data are presented. Large crystals exhibit a high degree of material plasticity, as well as a much higher strength than previously anticipated, on the order of 500 psi. Also revealed from the testing is the fact that crystal with a large number of grain boundaries developed less plasticity, and therefore less permanent deformation, than those with fewer grain boundaries.

Lee, H. M.↗