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14 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Small-sized specimen design with the provision for high-frequency bending-fatigue testing

The testing and study of emerging materials—such as additively manufactured materials—demands for specimen designs that are cost effective and time saving. Here the design of a small-sized bending-fatigue test specimen for an ultrasonic fatigue testing system is reported in this paper. The design is optimized based on the finite element analysis and analytical-solution results to achieve the proper vibration shape and stress distribution. The proposed design is evaluated in the high- and very-high-cycle fatigue regimes under 20-kHz frequency. Both simulation and testing results confirm that the desirable vibration mode occurs and the specimen fails at the designated test (gauge) section, where the maximum stress exists. The stress–life (S–N) curve is obtained for Inconel alloy 718 and indicates an expected trend.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Interactions between creep, fatigue and strain aging in two refractory alloys

The application of low-amplitude, high-frequency fatigue vibrations during creep testing of two strain-aging refractory alloys (molybdenum-base TZC and tantalum-base T-111) significantly reduced the creep strength of these materials. This strength reduction caused dramatic increases in both the first stage creep strain and the second stage creep rate. The magnitude of the creep rate acceleration varied directly with both frequency and A ratio (ratio of alternating to mean stress), and also varied with temperature, being greatest in the range where the strain-aging phenomenon was most prominent. It was concluded that the creep rate acceleration resulted from a negative strain rate sensitivity which is associated with the strain aging phenomenon in these materials. (A negative rate sensitivity causes flow stress to decrease with increasing strain rate, instead of increasing as in normal materials). By combining two analytical expressions which are normally used to describe creep and strain aging behavior, an expression was developed which correctly described the influence of temperature, frequency, and A ratio on the TZC creep rate acceleration.

Sheffler, K. D.↗
NASA NTRS1972

Interactions between creep, fatigue, and strain-aging in two refractory metal alloys.

The application of low-amplitude, high-frequency fatigue vibrations during creep testing of two strain-aging refractory alloys (molybdenum-base TZC and tantalum-base T-111) significantly reduced the creep strength of these materials. This strength reduction caused dramatic increases in both the first-stage creep strain and the second-stage creep rate. The magnitude of the creep rate acceleration varied directly with both frequency and A ratio (ratio of alternating to mean stress), and also varied with temperature, being greatest in the range where the strain-aging phenomenon was most prominent. It was concluded that the creep rate acceleration resulted from a negative strain rate sensitivity which is associated with the strain-aging phenomenon in these materials. (A negative rate sensitivity causes flow stress to decrease with increasing strain rate, instead of increasing as in normal materials.)

Sheffler, K. D.↗
NASA NTRS2014

Test Methodology Development for Experimental Structural Assessment of ASC Planar Spring Material for Long-Term Durability

A vibration-based testing methodology has been developed that will assess fatigue behavior of the metallic material of construction for the Advanced Stirling Convertor displacer (planar) spring component. To minimize the testing duration, the test setup is designed for base-excitation of a multiplespecimen arrangement, driven in a high-frequency resonant mode; this allows completion of fatigue testing in an accelerated period. A high performance electro-dynamic exciter (shaker) is used to generate harmonic oscillation of cantilever beam specimens, which are clasped on the shaker armature with specially-designed clamp fixtures. The shaker operates in closed-loop control with dynamic specimen response feedback provided by a scanning laser vibrometer. A test coordinator function synchronizes the shaker controller and the laser vibrometer to complete the closed-loop scheme. The test coordinator also monitors structural health of the test specimens throughout the test period, recognizing any change in specimen dynamic behavior. As this may be due to fatigue crack initiation, the test coordinator terminates test progression and then acquires test data in an orderly manner. Design of the specimen and fixture geometry was completed by finite element analysis such that peak stress does not occur at the clamping fixture attachment points. Experimental stress evaluation was conducted to verify the specimen stress predictions. A successful application of the experimental methodology was demonstrated by validation tests with carbon steel specimens subjected to fully-reversed bending stress; high-cycle fatigue failures were induced in such specimens using higher-than-prototypical stresses

fatigue testing machines↗
NASA NTRS2003

High-Frequency Testing of Composite Fan Vanes With Erosion-Resistant Coating Conducted

The mechanical integrity of hard, erosion-resistant coatings were tested using the Structural Dynamics Laboratory at the NASA Glenn Research Center. Under the guidance of Structural Mechanics and Dynamics Branch personnel, fixturing and test procedures were developed at Glenn to simulate engine vibratory conditions on coated polymer-matrix- composite bypass vanes using a slip table in the Structural Dynamics Laboratory. Results from the high-frequency mechanical bench testing, along with concurrent erosion testing of coupons and vanes, provided sufficient confidence to engine-endurance test similarly coated vane segments. The knowledge gained from this program will be applied to the development of oxidation- and erosion-resistant coatings for polymer matrix composite blades and vanes in future advanced turbine engines. Fan bypass vanes from the AE3007 (Rolls Royce America, Indianapolis, IN) gas turbine engine were coated by Engelhard (Windsor, CT) with compliant bond coatings and hard ceramic coatings. The coatings were developed collaboratively by Glenn and Allison Advanced Development Corporation (AADC)/Rolls Royce America through research sponsored by the High-Temperature Engine Materials Technology Project (HITEMP) and the Higher Operating Temperature Propulsion Components (HOTPC) project. High-cycle fatigue was performed through high-frequency vibratory testing on a shaker table. Vane resonant frequency modes were surveyed from 50 to 3000 Hz at input loads from 1g to 55g on both uncoated production vanes and vanes with the erosion-resistant coating. Vanes were instrumented with both lightweight accelerometers and strain gauges to establish resonance, mode shape, and strain amplitudes. Two high-frequency dwell conditions were chosen to excite two strain levels: one approaching the vane's maximum allowable design strain and another near the expected maximum strain during engine operation. Six specimens were tested per dwell condition. Pretest and posttest inspections were performed optically at up to 60 magnification and using a fluorescent-dye penetrant. Accumulation of 10 million cycles at a strain amplitude of two to three times that expected in the engine (approximately 670 Hz and 20g) led to the development of multiple cracks in the coating that were only detectable using fluorescent-dye penetrant inspection. Cracks were prevalent on the trailing edge and on the convex side of the midsection. No cracking or spalling was evident using standard optical inspection at up to 60 magnification. Further inspection may reveal whether these fine cracks penetrated the coating or were strictly on the surface. The dwell condition that simulated actual engine conditions produced no obvious surface flaws even after up to 80 million cycles had been accumulated at strain amplitudes produced at approximately 1500 Hz and 45g.

Bowman, Cheryl L.↗
NASA NTRS1985

Interaction of High-cycle and Low-cycle Fatigue of Haynes 188 Alloy at 1400 F Deg

The interaction of low-cycle fatigue (LCF) and high-cycle fatigue (HCF) was evaluated at the NASA Lewis Research Center on Haynes 188 alloy at 1400 F. Completely reversed, axial-load, strain-controlled fatigue tests were performed to determine the baseline data for this study. Additional specimens for interaction tests were cycled first at a high strain range for various small portions of expected LCF life followed by a step change to a low strain range to failure in HCF. Failure was defined as complete specimen separation. The resultant lives varied between 10 and 5000 cycles for the low-cycle fatigue tests and between 4500 and 3 million for the high-cycle fatigue tests. For the interaction tests the low-cycle-life portion ranged from 30 and 1000 applied cycles while the high-frequency life ranged from 300 and 300,000 cycles to failure. The step change results showed a significant nonlinear interaction in expected life. Application of a small part of the LCF life drastically decreased the available HCF life as compared with what would have been expected by the classical linear damage rule (LDR).

Peter T Bizon↗
NASA NTRS2001

Laser High-Cycle Thermal Fatigue of Pulse Detonation Engine Combustor Materials Tested

Pulse detonation engines (PDE's) have received increasing attention for future aerospace propulsion applications. Because the PDE is designed for a high-frequency, intermittent detonation combustion process, extremely high gas temperatures and pressures can be realized under the nearly constant-volume combustion environment. The PDE's can potentially achieve higher thermodynamic cycle efficiency and thrust density in comparison to traditional constant-pressure combustion gas turbine engines (ref. 1). However, the development of these engines requires robust design of the engine components that must endure harsh detonation environments. In particular, the detonation combustor chamber, which is designed to sustain and confine the detonation combustion process, will experience high pressure and temperature pulses with very short durations (refs. 2 and 3). Therefore, it is of great importance to evaluate PDE combustor materials and components under simulated engine temperatures and stress conditions in the laboratory. In this study, a high-cycle thermal fatigue test rig was established at the NASA Glenn Research Center using a 1.5-kW CO2 laser. The high-power laser, operating in the pulsed mode, can be controlled at various pulse energy levels and waveform distributions. The enhanced laser pulses can be used to mimic the time-dependent temperature and pressure waves encountered in a pulsed detonation engine. Under the enhanced laser pulse condition, a maximum 7.5-kW peak power with a duration of approximately 0.1 to 0.2 msec (a spike) can be achieved, followed by a plateau region that has about one-fifth of the maximum power level with several milliseconds duration. The laser thermal fatigue rig has also been developed to adopt flat and rotating tubular specimen configurations for the simulated engine tests. More sophisticated laser optic systems can be used to simulate the spatial distributions of the temperature and shock waves in the engine. Pulse laser high-cycle thermal fatigue behavior has been investigated on a flat Haynes 188 alloy specimen, under the test condition of 30-Hz cycle frequency (33-msec pulse period and 10-msec pulse width including a 0.2-msec pulse spike; ref. 4). Temperature distributions were calculated with one-dimensional finite difference models. The calculations show that that the 0.2-msec pulse spike can cause an additional 40 C temperature fluctuation with an interaction depth of 0.08 mm near the specimen surface region. This temperature swing will be superimposed onto the temperature swing of 80 C that is induced by the 10-msec laser pulse near the 0.53-mm-deep surface interaction region.

Zhu, Dong-Ming↗
NASA NTRS2004

Adaptive Controls Method Demonstrated for the Active Suppression of Instabilities in Engine Combustors

An adaptive feedback control method was demonstrated that suppresses thermoacoustic instabilities in a liquid-fueled combustor of a type used in aircraft engines. Extensive research has been done to develop lean-burning (low fuel-to-air ratio) combustors that can reduce emissions throughout the mission cycle to reduce the environmental impact of aerospace propulsion systems. However, these lean-burning combustors are susceptible to thermoacoustic instabilities (high-frequency pressure waves), which can fatigue combustor components and even the downstream turbine blades. This can significantly decrease the safe operating lives of the combustor and turbine. Thus, suppressing the thermoacoustic combustor instabilities is an enabling technology for lean, low-emissions combustors under NASA's Propulsion and Power Program. This control methodology has been developed and tested in a partnership of the NASA Glenn Research Center, Pratt & Whitney, United Technologies Research Center, and the Georgia Institute of Technology. Initial combustor rig testing of the controls algorithm was completed during 2002. Subsequently, the test results were analyzed and improvements to the method were incorporated in 2003, which culminated in the final status of this controls algorithm. This control methodology is based on adaptive phase shifting. The combustor pressure oscillations are sensed and phase shifted, and a high-frequency fuel valve is actuated to put pressure oscillations into the combustor to cancel pressure oscillations produced by the instability.

Kopasakis, George↗
DOE OSTI2025

Enhanced Design of Radiation Tolerant High-Temperature Structural Health Monitoring Sensors

Acoustic emission sensors are vital in the nuclear industry for real-time structural health monitoring and early detection of material degradation. By capturing high-frequency stress waves emitted from defects like cracks, corrosion, or fatigue, acoustic emission sensors enable non-invasive monitoring of critical components such as reactor vessels, piping, and containment structures. This technology supports predictive maintenance, enhances safety, and ensures regulatory compliance by providing early warnings of potential failures. It is also instrumental in research, particularly in material testing reactors, where it is used to monitor the behavior of fuels and materials under irradiation, by allowing the detection of cracking or other acoustic signals in real time. This enables the evaluation of performance and accident behavior of advanced fuel concepts.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
NASA NTRS2002

Fan Stall Flutter Flow Mechanism Studied

Modern turbofan engines employ a highly loaded fan stage with transonic or low-supersonic velocities in the blade-tip region. The fan blades are often prone to flutter at off-design conditions. Flutter is a highly undesirable and dangerous self-excited mode of blade oscillations that can result in high-cycle fatigue blade failure. The origins of blade flutter are not fully understood yet. Experimental data that can be used to clarify the origins of blade flutter in modern transonic fan designs are very limited. The Transonic Flutter Cascade Facility at the NASA Glenn Research Center was developed to experimentally study the details of flow mechanisms associated with fan flutter. The cascade airfoils are instrumented to measure high-frequency unsteady flow variations in addition to the steady flow data normally recorded in cascade tests. The test program measures the variation in surface pressure in response to the oscillation of one or more of the cascade airfoils. However, during the initial phases of the program when all airfoils were in fixed positions, conditions were found where significant time variations in the pressures near the airfoil leading edges could be observed.

Lepicovsky, Jan↗
NASA NTRS2005

Fatigue Behavior and Deformation Mechanisms in Inconel 718 Superalloy Investigated

The nickel-base superalloy Inconel 718 (IN 718) is used as a structural material for a variety of components in the space shuttle main engine (SSME) and accounts for more than half of the total weight of this engine. IN 718 is the bill-of-material for the pressure vessels of nickel-hydrogen batteries for the space station. In the case of the space shuttle main engine, structural components are typically subjected to startup and shutdown load transients and occasional overloads in addition to high-frequency vibratory loads from routine operation. The nickel-hydrogen battery cells are prooftested before service and are subjected to fluctuating pressure loads during operation. In both of these applications, the structural material is subjected to a monotonic load initially, which is subsequently followed by fatigue. To assess the life of these structural components, it is necessary to determine the influence of a prior monotonic load on the subsequent fatigue life of the superalloy. An insight into the underlying deformation and damage mechanisms is also required to properly account for the interaction between the prior monotonic load and the subsequent fatigue loading. An experimental investigation was conducted to establish the effect of prior monotonic straining on the subsequent fatigue behavior of wrought, double-aged, IN 718 at room temperature. First, monotonic strain tests and fully-reversed, strain-controlled fatigue tests were conducted on uniform-gage-section IN 718 specimens. Next, fully reversed fatigue tests were conducted under strain control on specimens that were monotonically strained in tension. Results from this investigation indicated that prior monotonic straining reduced the fatigue resistance of the superalloy particularly at the lowest strain range. Some of the tested specimens were sectioned and examined by transmission electron microscopy to reveal typical microstructures as well as the active deformation and damage mechanisms under each of the loading conditions. In monotonically strained specimens, deformation during the subsequent fatigue loading was mainly confined to the deformation bands initiated during the prior monotonic straining. This can cause dislocations to move more readily along the previously activated deformation bands and to pile up near grain boundaries, eventually making the grain boundaries susceptible to fatigue crack initiation. The mechanisms inferred from the microstructural investigation were extremely valuable in interpreting the influence of prior monotonic straining on the subsequent fatigue life of Inconel 718 superalloy.

Source record↗
NASA NTRS2002

Active Control of Combustor Instability Shown to Help Lower Emissions

In a quest to reduce the environmental impact of aerospace propulsion systems, extensive research is being done in the development of lean-burning (low fuel-to-air ratio) combustors that can reduce emissions throughout the mission cycle. However, these lean-burning combustors have an increased susceptibility to thermoacoustic instabilities, or high-pressure oscillations much like sound waves, that can cause severe high-frequency vibrations in the combustor. These pressure waves can fatigue the combustor components and even the downstream turbine blades. This can significantly decrease the safe operating life of the combustor and turbine. Thus, suppression of the thermoacoustic combustor instabilities is an enabling technology for lean, low-emissions combustors. Under the Aerospace Propulsion and Power Base Research and Technology Program, the NASA Glenn Research Center, in partnership with Pratt & Whitney and United Technologies Research Center, is developing technologies for the active control of combustion instabilities. With active combustion control, the fuel is pulsed to put pressure oscillations into the system. This cancels out the pressure oscillations being produced by the instabilities. Thus, the engine can have lower pollutant emissions and long life.The use of active combustion instability control to reduce thermo-acoustic-driven combustor pressure oscillations was demonstrated on a single-nozzle combustor rig at United Technologies. This rig has many of the complexities of a real engine combustor (i.e., an actual fuel nozzle and swirler, dilution cooling, etc.). Control was demonstrated through modeling, developing, and testing a fuel-delivery system able to the 280-Hz instability frequency. The preceding figure shows the capability of this system to provide high-frequency fuel modulations. Because of the high-shear contrarotating airflow in the fuel injector, there was some concern that the fuel pulses would be attenuated to the point where they would not be effective for control. Testing in the combustor rig showed that open-loop pulsing of the fuel was, in fact, able to effectively modulate the combustor pressure. To suppress the combustor pressure oscillations due to thermoacoustic instabilities, it is desirable to time the injection of the fuel so that it interferes with the instability. A closed-loop control scheme was developed that uses combustion pressure feedback and a phase-shifting controller to time the fuel-injection pulses. Some suppression of the pressure oscillations at the 280-Hz instability frequency was demonstrated (see the next figure). However, the overall peak-to- peak pressure oscillations in the combustor were only mildly reduced. Improvements to control hardware and control methods are being continued to gain improved closed-loop reduction of the pressure oscillations.pulse the fuel at

DeLaat, John C.↗
NASA NTRS1998

Thermal High- and Low-Cycle Fatigue Behavior of Thick Thermal Barrier Coating Systems

Ceramic thermal barrier coatings have received increasing attention for advanced gas turbine and diesel engine applications because of their ability to provide thermal insulation to engine components. However, the durability of these coatings under the severe thermal cycling conditions encountered in a diesel engine (ref. 1) still remains a major issue. In this research at the NASA Lewis Research Center, a high-power laser was used to investigate the thermal fatigue behavior of a yttria-stabilized zirconia coating system under simulated diesel engine conditions. The mechanisms of fatigue crack initiation and propagation, and of coating failure under complex thermal low-cycle fatigue (LCF, representing stop/start cycles) and thermal high-cycle fatigue (HCF, representing operation at 1300 rpm) are described. Continuous wave and pulse laser modes were used to simulate pure LCF and combined LCF/HCF, respectively (ref. 2). The LCF mechanism was found to be closely related to the coating sintering and creep at high temperatures. These creep strains in the ceramic coating led to a tensile stress state during cooling, thus providing the major driving force for crack growth under LCF conditions. The combined LCF/HCF tests induced more severe coating surface cracking, microspallation, and accelerated crack growth than did the pure LCF test. HCF thermal loads also facilitated lateral crack branching and ceramic/bond coat interface delaminations. HCF is associated with the cyclic stresses originating from the high-frequency temperature fluctuation at the ceramic coating surface. The HCF thermal loads act on the crack by a wedging mechanism (ref. 1), resulting in continuous crack growth at temperature. The HCF stress intensity factor amplitude increases with the interaction depth and temperature swing, and decreases with the crack depth. HCF damage also increases with the thermal expansion coefficient and the Young's modulus of the ceramic coating (refs. 1 and 3).

Miller, Robert A.↗