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NASA NTRS2026

Development and Experimental Validation of a Path-Dependent Spin Forming Finite Element Model

Spin forming is an advanced manufacturing process widely used in the aerospace and defense sectors to produce lightweight, high-strength cylindrical components with tight dimensional tolerances. This study explores the applicability of the path-dependent Mechanical Threshold Stress (MTS) constitutive model by simulating the evolution of geometry, machining forces, and plastic deformation during the spin forming of a 10-mm thick 6061-O aluminum cylinder. While numerical modeling of spin forming has advanced substantially over the past decade, systematic verification and experimental validation of material models remain limited, particularly in predicting through-thickness process evolution. The MTS model, incorporating a Voce hardening rule, is employed for its ability to represent cyclic loading, rapidly varying temperature fields, and strain rates characteristic of spin forming. Numerical convergence analysis indicates discretization uncertainties between 0.3% and 9.2% for key quantities of interest. Experimental validation demonstrates that the MTS model, when implemented with a verified mesh, accurately reproduces both elastic and plastic behavior of 6061-O aluminum, predicting peak roller loads within 11–18% of measurements, geometric tolerances within 3%, and plastic strain distributions within 10% of experimental values. Collectively, these results establish a validated computational framework for predictive spin-forming simulations with quantified confidence, providing a foundation for extension to other alloys, geometries, and forming conditions.

Spin forming↗

NASA NTRS1984

A study of environmental characterization of conventional and advanced aluminum alloys for selection and design. Phase 2: The breaking load test method

A technique is demonstrated for accelerated stress corrosion testing of high strength aluminum alloys. The method offers better precision and shorter exposure times than traditional pass fail procedures. The approach uses data from tension tests performed on replicate groups of smooth specimens after various lengths of exposure to static stress. The breaking strength measures degradation in the test specimen load carrying ability due to the environmental attack. Analysis of breaking load data by extreme value statistics enables the calculation of survival probabilities and a statistically defined threshold stress applicable to the specific test conditions. A fracture mechanics model is given which quantifies depth of attack in the stress corroded specimen by an effective flaw size calculated from the breaking stress and the material strength and fracture toughness properties. Comparisons are made with experimental results from three tempers of 7075 alloy plate tested by the breaking load method and by traditional tests of statistically loaded smooth tension bars and conventional precracked specimens.

Sprowls, D. O.↗

NASA NTRSDate not supplied

Simultaneous Development and Robust Optimization of a Microstructure Dependent Material

Recent microstructure characterization techniques combined with Symbolic Regression(SR)analysis has been proven to generate white box plasticity models well suited for incorporation into FEA software.The current work builds upon those efforts and demonstrates the applicability of Sequential Monte-Carlo (SMC) methods within SR analysis to condense model development and robust optimization into a single, co-dependent process. In this project, SMC methods provide a mechanism through which the observed microstructure features and associated variability can be incorporated into the discovery phase of model development and simultaneously recover approximate parameter distributions through SR analysis. The demonstration utilized a data set consisting of tensile test results from a limited number of sample specimens with corresponding EBSD data from which microstructure features were characterized.The maximum threshold stress model in the Visco-Plastic Self-Consistent (VPSC) code developed by Los Alamos National Laboratories was calibrated using mechanical test data.Synthetic volume elements with statistically equivalent microstructure were generated with DREAM3Dbased on the observed EBSD data. VPSC was used to simulate the corresponding tensile test response for each of the synthetic volume elements. The simulated microstructure and tensile test data was used astraining datafor SMC-SR algorithm and the resulting model was validated with data from the original empirical data set.

Karl Garbrecht↗

NASA NTRS2003

Modeling the Interactions Between Multiple Crack Closure Mechanisms at Threshold

A fatigue crack closure model is developed that includes interactions between the three closure mechanisms most likely to occur at threshold; plasticity, roughness, and oxide. This model, herein referred to as the CROP model (for Closure, Roughness, Oxide, and Plasticity), also includes the effects of out-of plane cracking and multi-axial loading. These features make the CROP closure model uniquely suited for, but not limited to, threshold applications. Rough cracks are idealized here as two-dimensional sawtooths, whose geometry induces mixed-mode crack- tip stresses. Continuum mechanics and crack-tip dislocation concepts are combined to relate crack face displacements to crack-tip loads. Geometric criteria are used to determine closure loads from crack-face displacements. Finite element results, used to verify model predictions, provide critical information about the locations where crack closure occurs.

Newman, John A.↗

NASA NTRS2013

Experimental Identification and Simulation of Time and/or Rate Dependent Reversible and Irreversible Deformation Regions for both a Titanium and Nickel Alloy

In this paper time and/or rate dependent deformation regions are experimentally mapped out as a function of temperature. It is clearly demonstrated that the concept of a threshold stress (a stress that delineate reversible and irreversible behavior) is valid and necessary at elevated temperatures and corresponds to the classical yield stress at lower temperatures. Also the infinitely slow modulus, (Es) i.e. the elastic modulus of the material if it was loaded at an infinitely slow strain rate, and the "dynamic modulus", modulus, Ed, which represents the modulus of the material if it is loaded at an infinitely fast rate are used to delineate rate dependent from rate independent regions. As demonstrated at elevated temperatures there is a significant difference between the two modulus values, thus indicating both significant time-dependence and rate dependence. In the case of the nickel-based super alloy, ME3, this behavior is also shown to be grain size specific. Consequently, at higher temperatures viscoelastic behavior exist below k (i.e., the threshold stress) and at stresses above k the behavior is viscoplastic. Finally a multi-mechanism, stress partitioned viscoelastic model, capable of being consistently coupled to a viscoplastic model is characterized over the full temperature range investigated for Ti-6-4 and ME3.

Arnold, Steven M.↗

NASA NTRS1993

A Modeling Investigation of Thermal and Strain Induced Recovery and Nonlinear Hardening in Potential Based Viscoplasticity

Specific forms for both the Gibb's and the complementary dissipation potentials were chosen such that a complete potential based multiaxial, isothermal, viscoplastic model was obtained. This model in general possesses three internal state variables (two scalars associated with dislocation density and one tensor associated with dislocation motion) both thermal and dynamic recovery mechanisms, and nonlinear kinematic hardening. This general model, although possessing associated flow and evolutionary laws, is shown to emulate three distinct classes of theories found in the literature, by modification of the driving threshold function F. A parametric study was performed on a specialized nondimensional multiaxial form containing only a single tensorial internal state variable (i.e., internal stress). The study was conducted with the idea of examining the impact of including a strain-induced recovery mechanism and the compliance operator, derived from the Gibb's potential, on the uniaxial and multiaxial response. One important finding was that inclusion of strain recovery provided the needed flexibility in modeling stress-strain and creep response of metals at low homologous temperatures, without adversely affecting the high temperature response. Furthermore, for nonproportional loading paths, the inclusion of the compliance operator had a significant influence on the multiaxial response, but had no influence on either uniaxial or proportional load histories.

Arnold, S. M.↗

NASA NTRS1983

A nonlinear fracture mechanics approach to the growth of small cracks

An analytical model of crack closure is used to study the crack growth and closure behavior of small cracks in plates and at notches. The calculated crack opening stresses for small and large cracks, together with elastic and elastic plastic fracture mechanics analyses, are used to correlate crack growth rate data. At equivalent elastic stress intensity factor levels, calculations predict that small cracks in plates and at notches should grow faster than large cracks because the applied stress needed to open a small crack is less than that needed to open a large crack. These predictions agree with observed trends in test data. The calculations from the model also imply that many of the stress intensity factor thresholds that are developed in tests with large cracks and with load reduction schemes do not apply to the growth of small cracks. The current calculations are based upon continuum mechanics principles and, thus, some crack size and grain structure exist where the underlying fracture mechanics assumptions become invalid because of material inhomogeneity (grains, inclusions, etc.). Admittedly, much more effort is needed to develop the mechanics of a noncontinuum. Nevertheless, these results indicate the importance of crack closure in predicting the growth of small cracks from large crack data.

Newman, J. C., Jr.↗

NASA NTRS2004

Durability Assessment of Gamma Tial

Gamma TiAl was evaluated as a candidate alloy for low-pressure turbine blades in aeroengines. The durability of g-TiAl was studied by examining the effects of impact or fretting on its fatigue strength. Cast-to-size Ti-48Al-2Cr-2Nb was studied in impact testing with different size projectiles at various impact energies as the reference alloy and subsequently fatigue tested. Impacting degraded the residual fatigue life. However, under the ballistic impact conditions studied, it was concluded that the impacts expected in an aeroengine would not result in catastrophic damage, nor would the damage be severe enough to result in a fatigue failure under the anticipated design loads. In addition, other gamma alloys were investigated including another cast-to-size alloy, several cast and machined specimens, and a forged alloy. Within this Ti-48-2-2 family of alloys aluminum content was also varied. The cracking patterns as a result of impacting were documented and correlated with impact variables. The cracking type and severity was reasonably predicted using finite element models. Mean stress affects were also studied on impact-damaged fatigue samples. The fatigue strength was accurately predicted based on the flaw size using a threshold-based, fracture mechanics approach. To study the effects of wear due to potential applications in a blade-disk dovetail arrangement, the machined Ti-47-2-2 alloy was fretted against In-718 using pin-on-disk experiments. Wear mechanisms were documented and compared to those of Ti-6Al-4V. A few fatigue samples were also fretted and subsequently fatigue tested. It was found that under the conditions studied, the fretting was not severe enough to affect the fatigue strength of g-TiAl.

Draper, Susan L.↗

NASA NTRS2017

Reversible and Irreversible Time-Dependent Behavior of GRCop-84

A series of mechanical tests were conducted on a high-conductivity copper alloy, GRCop-84, in order to understand the time dependent response of this material. Tensile, creep, and stress relaxation tests were performed over a wide range of temperatures, strain rates, and stress levels to excite various amounts of time-dependent behavior. At low applied stresses the deformation behavior was found to be fully reversible. Above a certain stress, termed the viscoelastic threshold, irreversible deformation was observed. At these higher stresses the deformation was observed to be viscoplastic. Both reversible and irreversible regions contained time dependent deformation. These experimental data are documented to enable characterization of constitutive models to aid in design of high temperature components.

viscoelasticity↗

NASA NTRS2004

Distribution of Inclusion-Initiated Fatigue Cracking in Powder Metallurgy Udimet 720 Characterized

In the absence of extrinsic surface damage, the fatigue life of metals is often dictated by the distribution of intrinsic defects. In powder metallurgy (PM) alloys, relatively large defects occur rarely enough that a typical characterization with a limited number of small volume fatigue test specimens will not adequately sample inclusion-initiated damage. Counterintuitively, inclusion-initiated failure has a greater impact on the distribution in PM alloy fatigue lives because they tend to have fewer defects than their cast and wrought counterparts. Although the relative paucity of defects in PM alloys leads to higher mean fatigue lives, the distribution in observed lives tends to be broader. In order to study this important failure initiation mechanism without expending an inordinate number of specimens, a study was undertaken at the NASA Glenn Research Center where known populations of artificial inclusions (seeds) were introduced to production powder. Fatigue specimens were machined from forgings produced from the seeded powder. Considerable effort has been expended in characterizing the crack growth rate from inclusion-initiated cracks in seeded PM alloys. A rotating and translating positioning system, with associated software, was devised to map the surface inclusions in low-cycle fatigue (LCF) test bars and to monitor the crack growth from these inclusions. The preceding graph illustrates the measured extension in fatigue cracks from inclusions on a seeded LCF test bar subjected to cyclic loading at a strain range of 0.8 percent and a strain ratio (max/min) of zero. Notice that the observed inclusions fall into three categories: some do not propagate at all (arrest), some propagate with a decreasing crack growth rate, and a few propagate at increasing rates that can be modeled by fracture mechanics. The following graph shows the measured inclusion-initiated crack growth rates from 10 interrupted LCF tests plotted against stress intensities calculated for semi-elliptical cracks with the observed surface lengths. The expected scatter in the crack growth rates for stress intensity ranges near threshold is observed. These data will be used to help determine the distribution in growth rates of cracks emanating from inclusions as well as the proportion of cracks that arrest under various loading conditions.

Bonacuse, Peter J.↗

NASA NTRS1988

A model for life predictions of nickel-base superalloys in high-temperature low cycle fatigue

Extensive characterization of low-cycle fatigue damage mechanisms was performed on polycrystalline Rene 80 and IN100 tested in the temperature range from 871 to 1000 C. Low-cycle fatigue life was found to be dominated by propagation of microcracks to a critical size governed by the maximum tensile stress. A model was developed which incorporates a threshold stress for crack extension, a stress-based crack growth expression, and a failure criterion. The mathematical equivalence between this mechanistically based model and the strain-life low-cycle fatigue law was demonstrated using cyclic stress-strain relationships. The model was shown to correlate the high-temperature low-cycle fatigue data of the different nickel-base superalloys considered in this study.

Romanoski, Glenn R.↗

NASA NTRS1993

Environment enhanced fatigue crack propagation in metals: Inputs to fracture mechanics life prediction models

This report is a critical review of both environment-enhanced fatigue crack propagation data and the predictive capabilities of crack growth rate models. This information provides the necessary foundation for incorporating environmental effects in NASA FLAGRO and will better enable predictions of aerospace component fatigue lives. The review presents extensive literature data on 'stress corrosion cracking and corrosion fatigue.' The linear elastic fracture mechanics approach, based on stress intensity range (Delta(K)) similitude with microscopic crack propagation threshold and growth rates, provides a basis for these data. Results are presented showing enhanced growth rates for gases (viz., H2 and H2O) and electrolytes (e.g. NaCl and H2O) in aerospace alloys including: C-Mn and heat treated alloy steels, aluminum alloys, nickel-based superalloys, and titanium alloys. Environment causes purely time-dependent accelerated fatigue crack growth above the monotonic load cracking threshold (KIEAC) and promotes cycle-time dependent cracking below (KIEAC). These phenomenon are discussed in terms of hydrogen embrittlement, dissolution, and film rupture crack tip damage mechanisms.

Gangloff, Richard P.↗

NASA NTRS1992

Mechanisms of fatigue crack retardation following single tensile overloads in powder metallurgy aluminum alloys

In ingot metallurgy (IM) alloys, the number of delay cycles following a single tensile overload typically increases from a minimum at an intermediate baseline stress intensity range, Delta-K(B), with decreasing Delta-K(B) approaching threshold and increasing Delta-K(B) approaching unstable fracture to produce a characteristic 'U' shaped curve. Two models have been proposed to explain this behavior. One model is based on the interaction between roughness and plasticity-induced closure, while the other model only utilizes plasticity-induced closure. This article examines these models, using experimental results from constant amplitude and single overload fatigue tests performed on two powder metallurgy (PM) aluminum alloys, AL-905XL and AA 8009. The results indicate that the 'U'-shaped curve is primarily due to plasticity-induced closure, and that the plasticity-induced retardation effect is through-thickness in nature, occurring in both the surface and interior regions. However, the retardation effect is greater at the surface, because the increase in plastic strain at the crack tip and overload plastic zone size are larger in the plane-stress surface regions than in the plane-strain interior regions. These results are not entirely consistent with either of the proposed models.

Bray, G. H.↗

NASA NTRS1990

Corrosion fatigue crack propagation in metals

This review assesses fracture mechanics data and mechanistic models for corrosion fatigue crack propagation in structural alloys exposed to ambient temperature gases and electrolytes. Extensive stress intensity-crack growth rate data exist for ferrous, aluminum and nickel based alloys in a variety of environments. Interactive variables (viz., stress intensity range, mean stress, alloy composition and microstructure, loading frequency, temperature, gas pressure and electrode potential) strongly affect crack growth kinetics and complicate fatigue control. Mechanistic models to predict crack growth rates were formulated by coupling crack tip mechanics with occluded crack chemistry, and from both the hydrogen embrittlement and anodic dissolution/film rupture perspectives. Research is required to better define: (1) environmental effects near threshold and on crack closure; (2) damage tolerant life prediction codes and the validity of similitude; (3) the behavior of microcrack; (4) probes and improved models of crack tip damage; and (5) the cracking performance of advanced alloys and composites.

Gangloff, Richard P.↗

NASA NTRSDate not supplied

Softening the Gap between Wöhler and Paris – New Approaches for Fatigue Analysis –

Fatigue analysis tools can vary across industries. For example, automotive engineers often use the Wöhler (S-N) approach to design for safe-life, while aerospace engineers prioritize damage tolerance and inspection intervals, relying instead on crack growth models such as Paris’ law. Although both approaches may deal with the control of cracks in similar materials, their analysis tools and material characterizations are fundamentally distinct. This divide mirrors the classic split between stress-based strength analysis and linear elastic fracture mechanics. However, modern nonlinear models that incorporate material softening, such as cohesive laws, blur this boundary and capture fracture behaviors across scales. This presentation describes the CF23 fatigue model, which uses cohesive softening to link S-N crack initiation with crack propagation rates. CF23 spans the full fatigue spectrum, from initial propagation transients to steady-state growth and threshold conditions, offering a unified framework that bridges Wöhler and Paris-based methodologies. Example applications include fatigue crack propagation transients in adhesive interfaces and skin/stiffener separation.

cohesive elements↗

NASA NTRS2010

Placental Induced Growth Factor (PIGf) in Coronary Artery Disease

Our previous studies on normal human lymphocytes have shown a five-fold increase (p less than 0.001) in angiogenic inducers such as Placental Induced Growth Factor (PIGf) in physiologically stressful environments such as modeled microgravity, a space analog. This suggests de-regulation of cardiovascular signalling pathways indicated by upregulation of PIGf. In the current study, we measured PIGf in the plasma of 33 patients with and without coronary artery disease (CAD) to investigate whether such disease is associated with increased levels of PIGf. A control consisting of 31 sex matched apparently healthy subjects was also included in the study. We observed that the levels of PIGf in CAD patients were significantly increased compared to those in healthy control subjects (p less than 0.001) and usually increased beyond the clinical threshold level (greater than 27ng/L). The mechanisms leading to up-regulation of angiogenic factors and the adaptation of organisms to stressful environments such as isolation, high altitude, hypoxia, ischemia, microgravity, increased radiation, etc are presently unknown and require further investigation in spaceflight and these other physiologically stressed environments.

Sundaresan, Alamelu↗

NASA NTRS2009

A Cell Kinetic Model of Granulocytopoiesis Under Radiation Exposure: Extension from Murines to Canines and Humans

Space radiation poses significant challenges to space travel, and it is essential to understand the possible adverse effects from space radiation exposure to the radiosensitive organ systems that are important for immediate survival of human, e.g., the hematopoietic system. In this presentation a biomathematical model of granulocytopoiesis is described and used to analyze the blood granulocyte changes seen in the blood of mammalians under continuous and acute radiation exposure. This is one of a set of hematopoietic models that have been successfully utilized to simulate and interpret the experimental data of acute and chronic radiation on rodents. We discuss the underlying implicit regulation mechanism and the biological relevance of the kinetic parameters estimation method. Extension of the model to predictions in dogs and humans systems indicates that the modeling results are consistent with the cumulative experimental and empirical data from various sources. This implies the potential to integrate the models into one united system for monitoring the hematopoietic response of various species under irradiation. Based on the evidence of threshold responses of dogs to extended periods of low daily dose exposures, we discuss the potential health risks of the space traveler under chronic stress of low-dose irradiation and the possibly encountered Solar Particle Events.

Hu, Shaowen↗

NASA NTRS1988

Mechanism of rapid suppression of cell expansion in cucumber hypocotyls after blue-light irradiation

Rapid suppression of hypocotyl elongation by blue light in cucumber (Cucumis sativus L.) was studied to examine possible hydraulic and wall changes responsible for diminished growth. Cell-sap osmotic pressure, measured by vapor-pressure osmometry, was not decreased by blue light; turgor pressure, measured by the pressure-probe technique, remained constant during the growth inhibition; and stem hydraulic conductance, measured by dynamic and static methods, was likewise unaffected by blue light. Wall yielding properties were assessed by the pressure-block technique for in-vivo stress relaxation. Blue light reduced the initial rate of relaxation by 77%, but had little effect on the final amount of relaxation. The results demonstrate that blue irradiation acts to decrease the wall yielding coefficient, but not the yield threshold. Stress-strain (Instron) analysis showed that irradiation of the seedlings had little effect on the mechanical extensibilities of the isolated wall. The results indicate that blue light can reduce cell-wall loosening without affecting bulk viscoelastic properties, and indicate a chemorheological mechanism of cell-wall expansion.

NASA Discipline Number 40-30↗