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Anisotropic materials ductile fracture involving crack initation and propagation, using Dugdale mathematical model
An in-depth tutorial on the constitutive equations for elastic, anisotropic materials is presented. Basic concepts are introduced that are used to characterize materials, and notions about how anisotropic material deform are presented. Hooke s law and the Duhamel-Neuman law for isotropic materials are presented and discussed. Then, the most general form of Hooke s law for elastic anisotropic materials is presented and symmetry requirements are given. A similar presentation is also given for the generalized Duhamel-Neuman law for elastic, anisotropic materials that includes thermal effects. Transformation equations for stress and strains are presented and the most general form of the transformation equations for the constitutive matrices are given. Then, specialized transformation equations are presented for dextral rotations about the coordinate axes. Next, concepts of material symmetry are introduced and criteria for material symmetries are presented. Additionally, engineering constants of fully anisotropic, elastic materials are derived from first principles and the specialized to several cases of practical importance.
The objective of this project is to develop and demonstrate a capability for computing stress intensity factors in generally anisotropic materials. These objectives have been met. The primary deliverable of this project is this report and the information it contains. In addition, we have delivered the source code for a subroutine that will compute stress intensity factors for anisotropic materials encoded in both the C and Python programming languages and made available a version of the FRANC3D program that incorporates this subroutine. Single crystal super alloys are commonly used for components in the hot sections of contemporary jet and rocket engines. Because these components have a uniform atomic lattice orientation throughout, they exhibit anisotropic material behavior. This means that stress intensity solutions developed for isotropic materials are not appropriate for the analysis of crack growth in these materials. Until now, a general numerical technique did not exist for computing stress intensity factors of cracks in anisotropic materials and cubic materials in particular. Such a capability was developed during the project and is described and demonstrated herein.
General thin shell equations derived for plane anisotropic materials
Optimum thin wall pressure vessels of anisotropic materials of monolithic and filamentary construction
The behavior of beams made of anisotropic material was investigated in order to develop an appropriate model of such behavior. Closed form solutions of the problem were derived using two alternative approaches. In the first approach, the axial displacements are expanded as a series of eigenwarpings. In the second approach, the axial stresses are expanded as a series of eigenwarpings. A finite element solution was also derived using the same displacement field as in the first approach.
Design synthesis relationship derived for primary structural weight of membrane type pressure vessels of anisotropic materials
The purpose is to develop life prediction models for coated anisotropic materials used in gas temperature airfoils. Two single crystal alloys and two coatings are now being tested. These include PWA 1480; Alloy 185; overlay coating, PWA 286; and aluminide coating, PWA 273. Constitutive models are also being developed for these materials to predict the plastic and creep strain histories of the materials in the lab tests and for actual design conditions. This nonlinear material behavior is particularily important for high temperature gas turbine applications and is basic to any life prediction system.
The purpose of this work is the development of a unified, cyclic, viscoplastic model for anisotropic materials. The first part of the paper presents the foundations of the model in the framework of thermodynamics with internal variables. The second part considers the particular case of cubic symmetry, and addresses the cyclic behavior of a nickel-base single-crystal superalloy, CMSX-2, at high temperature (950 C).
The intent of this program is to develop a basic understanding of cyclic creep-fatigue deformation mechanisms and damage accumulation, a capability for reliable life prediction, and the ability to model the constitutive behavior of anisotropic single crystal (SC) and directionally solidified or recrystallized (DSR) comprise the program, and the work breakdown for each option reflects a distinct concern for two classes of anisotropic materials, SC and DSR materials, at temperatures encountered in the primary gas path (airfoil temperatures), and at temperatures typical of the blade root attachment and shank area. Work directed toward the higher temperature area of concern in the primary gas path includes effects of coatings on the behavior and properties of the materials of interest. The blade root attachment work areas will address the effects of stress concentrations associated with attachment features.
Ultrasonics probe direction of tile fibers. Hand-held acoustic transducer determines fiber orientation of heat resistant tiles. Transducers head placed on outer surface of painted tile. Signals from receiving transducers displayed on two-channel oscilloscope. Application suggests extending technique to inspection of other anisotropic materials. Plywood and fiber/epoxy composites examined to determine fiber direction; ultrasonics used to find direction of roll in sheet metal and other rolled products.
The results are presented of a program designed to develop life prediction and constitutive models for two coated single crystal alloys used in gas turbine airfoils. The two alloys are PWA 1480 and Alloy 185. The two oxidation resistant coatings are PWA 273, an aluminide coating, and PWA 286, an overlay NiCoCrAlY coating. To obtain constitutive and fatigue data, tests were conducted on uncoated and coated specimens loaded in the CH76 100 CH110 , CH76 110 CH110 , CH76 111 CH110 and CH76 123 CH110 crystallographic directions. Two constitutive models are being developed and evaluated for the single crystal materials: a micromechanic model based on crystallographic slip systems, and a macroscopic model which employs anisotropic tensors to model inelastic deformation anisotropy. Based on tests conducted on the overlay coating material, constitutive models for coatings also appear feasible and two initial models were selected. A life prediction approach was proposed for coated single crystal materials, including crack initiation either in the coating or in the substrate. The coating initiated failures dominated in the tests at load levels typical of gas turbine operation. Coating life was related to coating stress/strain history which was determined from specimen data using the constitutive models.
The development of directionally solidified and single crystal alloys is perhaps the most important recent advancement in hot section materials technology. The objective is to develop knowledge that enables the designer to improve anisotropic gas turbine parts to their full potential. Two single crystal alloys selected were PWA 1480 and Alloy 185. The coatings selected were an overlay coating, PWA 286, and an aluminide diffusion coating, PWA 273. The constitutive specimens were solid and cylindrical; the fatigue specimens were hollow and cylindrical. Two thicknesses of substrate are utilized. Specimens of both thickness (0.4 and 1.5 mm) will be coated and then tested for tensile, creep, and fatigue properties.
A constitutive equation was developed to predict the inelastic thermomechanical response of single crystal turbine blades. These equations are essential for developing accurate finite element models of hot section components and contribute significantly to the understanding and prediction of crack initiation and propagation. The method used was limited to unified state variable constitutive equations. Two approaches to developing an anisotropic constitutive equation were reviewed. One approach was to apply the Stouffer-Bodner representation for deformation induced anisotropy to materials with an initial anisotropy such as single crystals. The second approach was to determine the global inelastic strain rate from the contribution of the slip in each of the possible crystallographic slip systems. A three dimensional finite element is being developed with a variable constitutive equation link that can be used for constitutive equation development and to predict the response of an experiment using the actual specimen geometry and loading conditions.
The applicability of a technique for determining the optical constants of soil or aerosol components on the basis of measurements of the reflectance or transmittance of inhomogeneous samples of component material is investigated. Optical constants for a sample of very pure quartzite were obtained by a specular reflection technique and line parameters were calculated by classical dispersion theory. Predictions of the reflectance of powdered quartz were then derived from optical constants measured for the anisotropic quartz and for pure quartz crystals, and compared with experimental measurements. The calculated spectra are found to resemble each other moderately well in shape, however the reflectance level calculated from the psuedo-optical constants (quartzite) is consistently below that calculated from quartz values. The spectrum calculated from the quartz optical constants is also shown to represent the experimental nonrestrahlen features more accurately. It is thus concluded that although optical constants derived from inhomogeneous materials may represent the spectral features of a powdered sample qualitatively a quantitative fit to observed data is not likely.
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Beam theory plays an important role in structural analysis. The basic assumption is that initially plane sections remain plane after deformation, neglecting out-of-plane warpings. Predictions based on these assumptions are accurate for slender, solid, cross-sectional beams made out of isotropic materials. The beam theory derived in this paper from variational principles is based on the sole kinematic assumption that each section is infinitely rigid in its own plane, but free to warp out of plane. After a short review of the Bernoulli and Saint-Venant approaches to beam theory, a set of orthonormal eigenwarpings is derived. Improved solutions can be obtained by expanding the axial displacements or axial stress distribution in series of eigenwarpings and using energy principles to derive the governing equations. The improved Saint-Venant approach leads to fast converging solutions and accurate results are obtained considering only a few eigenwarping terms.
This report presents the results of the first year of a program designed to develop life prediction and constitutive models for two coated single crystal alloys used in gas turbine airfoils. The two alloys are PWA 1480 and Alloy 185. The two oxidation resistant coatings are PWA 273, an aluminide coating, and PWA 286, an overlay NiCoCrAlY coating. To obtain constitutive and/or fatigue data, tests were conducted on coated and uncoated PWA 1480 specimens tensilely loaded in the 100 , 110 , 111 , and 123 directions. A literature survey of constitutive models was completed for both single crystal alloys and metallic coating materials; candidate models were selected. One constitutive model under consideration for single crystal alloys applies Walker's micromechanical viscoplastic formulation to all slip systems participating in the single crystal deformation. The constitutive models for the overlay coating correlate the viscoplastic data well. For the aluminide coating, a unique test method is under development. LCF and TMF tests are underway. The two coatings caused a significant drop in fatigue life, and each produced a much different failure mechanism.