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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1999

Flow Trajectories in Friction Stir Welding

In the Friction Stir Welding (FSW) process, a rotating, shouldered tool with a threaded pin is inserted under pressure along the seam of two pieces of metal which are tightly clamped together, and secured against a rigid anvil underneath. The rotating pin travels along the seam and through a combination of pressure and friction heating produces a zone of plastic deformation around the pin within the workpiece on either side of the seam. As the pin is moved in the direction of welding, the plasticised material moves around the tool and bonds together behind it. The elements of the material flow behavior are a combination of three elements. There is a rotational transport of material being carried around the tool, extrusion of material being forced around the pin on both sides into the cavity created behind it, and a lifting and dropping of material as it is stirred and mixed by the rotating action of the pin. It was assumed that rotational motion of the plastic zone is the primary mechanism for transport of material around the welding tool. A kinematic mathematical model was used to compute trajectories of material movement for various distributions of rotational slip within the plastic zone. These trajectories were then compared with the results of an experiment that produced radiographs of markers embedded in a workpiece that was welded with the FSW process. It was assumed that the copper wire markers retained their original length as the aluminum material flowed around them. The kinematic model included a constraint so that the displacements were such that the total length of the wire markers did not increase after deformation. There was good agreement between the calculated trajectories for the case of localized slip at the outer surface of the plastic deformation zone and the radiographs of the copper wire markers. The trajectories differed markedly from the radiograph traces when a distributed slip zone was assumed. It was concluded that the flow field could be described generally by a rotating plug model with slip occurring on the surface at the outer boundary of the plastic zone.

Bernstein, Edward L.↗
NASA NTRS1996

Manifestations of Dynamic Strain Aging in Soft-Oriented NiAl Single Crystals

The tensile and compressive properties of six NiAl-base single-crystal alloys have been investigated at temperatures between 77 and 1200 K. The normalized critical resolved shear stresses (CRSS/E) and work-hardening rates (Theta/E) for these alloys generally decreased with increasing temperature. However, anomalous peaks or plateaus for these properties were observed in conventional purity (CPNiAl), Si-doped (NiAl-Si), C-doped low Si (UF-NiAl1), and Mo-doped (NiAl-Mo) alloys at intermediate temperatures (600 to 1000 K). This anomalous behavior was not observed in high-purity, low interstitial material (HP-NiAl). Low or negative strain-rate sensitivities (SRS) also were observed in all six alloys in this intermediate temperature range. Coincident with the occurrence of negative strain-rate sensitivities was the observation of serrated stress-strain curves in the CPNiAl and NiAl-Si alloys. These phenomena have been attributed to dynamic strain aging (DSA). Chemical analysis of the alloys used in this study suggests that the main specie responsible for strain aging in NiAl is C but indicate that residual Si impurities can enhance the strain aging effects. The corresponding dislocation microstructures at low temperatures (300 to 600 K) were composed of well-defined cells. At intermediate temperatures (600 to 900 K), either poorly defined cells or coarse bands of localized slip, reminiscent of the vein structures observed in low-cycle fatigue specimens deformed in the DSA regime, were observed in conventional purity, Si-doped, and in Mo-doped alloys. In contrast, a well-defined cell structure persisted in the low interstitial, high-purity alloy. At elevated temperatures (greater than or equal to 1000 K), more uniformly distributed dislocations and sub-boundaries were observed in all alloys. These observations are consistent with the occurrence of DSA in NiAl single-crystal alloys at intermediate temperatures.

Weaver, M. L.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-17800-DND

Currently, there are two national challenge problems that guide much of the research in durability and damage tolerance at NASA Langley. The first, Airframe Digital Twin, is a concept that combines as-built vehicle components, as-experienced loads and environments, and other vehicle-specific characteristics to enable ultrahigh fidelity modeling of aircraft and spacecraft throughout their service lives. The second, Materials Genome Initiative, is an analog to the Human Genome Project, and is intended to improve the rate at which materials scientists can discover, understand fundamental physics, and improve material systems. This presentation will highlight several research projects ongoing at NASA Langley that are in support of the above challenge problems. Two of those topics will be the subject of detailed discussion. First, investigations of microstructurally-small fatigue cracking (MSFC) in Al-2Cu and Al-4Cu, fabricated in-house, will be presented. Single- and oligo-crystals of Al-Cu specimens were loaded in uniaxial fatigue, while high-resolution in-situ measurements of deformation were made using image correlation (IC) in a scanning-electron microscope (SEM). The Al-Cu specimens were then replicated as crystal plasticity finite element models (CPFEM), where evolution of slip localization near grain boundaries was computed. Comparison among experiment and CPFEM is made. In addition, XRay diffraction measurements of the as-fabricated specimens were carried out, where direct measurements of the embedded copper precipitates were made, and their influence on growing MSFCs were directly observed. The second main topic will illustrate ongoing work in the area of so-called damage-sensing particles. In this work, shape-memory alloys are embedded in an aluminum alloy matrix. Upon the propagation of a fatigue crack, these particles undergo a strain-induced phase transformation which is detected using an acoustic sensor, providing real-time information on propagating cracks. Experiments and simulations regarding the development of this system will also be detailed.

Jacob Hochhalter↗
NASA NTRS1993

Intrinsic fatigue crack growth rates for Al-Li-Cu-Mg alloys in vacuum

The influences of microstructure and deformation mode on inert environment intrinsic fatigue crack propagation were investigated for Al-Li-Cu-Mg alloys AA2090, AA8090, and X2095 compared to AA2024. The amount of coherent shearable delta-prime (Al3Li) precipitates and extent of localized planar slip deformation were reduced by composition (increased Cu/Li in X2095) and heat treatment (double aging of AA8090). Intrinsic growth rates, obtained at high constant K(max) to minimize crack closure and in vacuum to eliminate any environmental effect, were alloy dependent; da/dN varied up to tenfold based on applied Delta-K or Delta-K/E. When compared based on a crack tip cyclic strain or opening displacement parameter, growth rates were equivalent for all alloys except X2095-T8, which exhibited unique fatigue crack growth resistance. Tortuous fatigue crack profiles and large fracture surface facets were observed for each Al-Li alloy independent of the precipitates present, particularly delta-prime, and the localized slip deformation structure. Reduced fatigue crack propagation rates for X2095 in vacuum are not explained by either residual crack closure or slip reversibility arguments; the origin of apparent slip band facets in a homogeneous slip alloy is unclear.

Slavik, D. C.↗
NASA NTRS1988

Geological and vegetational applications of Shuttle Imaging Radar-B, Mineral County, Nevada

Multiple-incidence angle and multi-azimuth radar data were acquired from a Shuttle platform over test sites in Nevada in October 1984. An attempt was made to correlate these data with ground features for the purpose of evaluating the use of such data for geological and vegetational assessment. Standard ecological parameters with respect to the flora (community composition, dominance, and relative cover) were recorded in the field at the time of overflight. Although a total of 33 species representing 11 plant families were recognized, and plant cover ranged from 13 to 26 percent, radar data could not be used to separate plant communities. The signal return is more a function of abiotic conditions than vegetative characteristics. Illumination geometry plays an important role in the ability to detect strike-slip and dip-slip faults. Local incidence angle is the most important parameter, and SIR-B data takes with small incidence angles are superior for identifying certain styles of faulting. Look direction is critical for detecting faults with a dip-slip component. New structural features were not observed. Problems with radar antenna power and recording significantly affected data quality.

Borengasser, M. X.↗
NASA NTRS2005

Crustal Deformation and the Seismic Cycle Across the Kodiak Islands, Alaska

The Kodiak Islands are located approximately 120 to 250 km from the Alaska-Aleutian Trench - and are within the southern extent of the 1964 Prince William Sound (M(sub w) = 9.2) earthquake rupture zone. Here we report new campaign GPS results (1993-2001) from northern Kodiak Island. The rate and orientation of the horizontal velocities, relative to a fixed North America, range from 25.3 plus or minus 1.4 mm/yr at N32.9 deg. W plus or minus 2.5 to 8.5 plus or minus 1.0 mm/yr at N59.7 deg. W plus or minus 6.5 deg. In addition to the northern Kodiak data, we analyzed data from three southern Kodiak Island stations. The inland stations from both the northern and southern networks indicate a counterclockwise rotation of the velocity vectors. These results are consistent with the hypothesis that the difference between the Pacific-North American plate motion and the orientation of the down going slab would lead to 4-8 mm/yr of left-lateral slip above the unlocked, down-dip portion of the main thrust zone. The northern and southern Kodiak geodetic data are consistent with a model that includes the viscoelastic response to (1) a downgoing Pacific plate interface that is locked at shallow depths, (2) local coseismic slip in the 1964 earthquake, and (3) interseismic creep down dip from the seismogenic zone. Based on the pre-1964 and post-1944 earthquake history, as well as the pattern of interseismic earthquakes across the plate boundary zone, we hypothesize that in southern Kodiak some strain is released in moderate to large earthquakes between the occurrences of great earthquakes like the 1964 event.

Sauber, Jeanne↗
NASA NTRS1985

Elastic-plastic deformation of a metal-matrix composite coupon with a center slot

A comprehensive experimental analysis of deformations of the surface of a metal-matrix specimen is reported. The specimen is a 6-ply 0 + or - 45 sub s boron-aluminum tensile coupon with a central slot. Moire interferometry is used for high-sensitivity whole-field measurements of in-plane displacements. Normal and shear strains are calculated from displacement gradients. Displacement fields are analyzed at various load levels from 15% to 95% of the failure load. Deformations of the boron fibers could be distinguished from those of the matrix. Highly localized plastic slip zones occur tangent to the ends of the slot. Shear strains and concurrent transverse compressive strains in the slip zones reach approximately 10% and 1%, respectively. Upon unloading, elastic recovery in surrounding regions causes a reverse plastic shear strain in the slip zone of about 4%. Longitudinal normal strains on the unslotted ligament peak at the slot boundary at about 1% strain. The strain concentration factor at the end of the slot decreases with load level and the advance of plasticity.

Post, D.↗
NASA NTRS1987

Deformation of a metal-matrix tensile coupon with a central slot - An experimental study

A metal-matrix specimen was investigated using high-sensitivity moire interferometry. In-plane displacement fields were analyzed at various load levels from 15 to 95 percent of the failure load. Normal and shear strains were determined from displacement gradients. Highly localized plastic slip zones occured in the ductile aluminum matrix tangent to the ends of the slot. Shear strains in the slip zone were an order of magnitude greater than the largest normal strains in the specimen. The shear-strain concentration factor rose dramatically with the onset of plastic slip and continued to rise gradually with load to 95 percent of the failure load. Upon unloading, shear strains in the slip zone remained precariously high.

Post, Daniel↗
NASA NTRS1992

Structural review of the Vredefort dome

The structure of the older-than-3.2-Ga Archean basement and Archean-to-Precambrian sedimentary/volcanic rocks (3.07 to ca. 2.2 Ga) in the center of the Witwatersrand Basin to the southwest of Johannesburg (South Africa) is dominated by the ca. 2.0-Ga megascopic Vredefort 'Dome' structure. The effect of the 'Vredefort event' is demonstrably large and is evident within a northerly arc of about 100 km radius around the granitic core of the structure. Northerly asymmetric overturning of the strata is observed within the first 17 km (strata is horizontal in the south), followed by a 40-km-wide rim synclinorium. Fold and fault structures (normal, reverse, and strike-slip) are locally as well as regionally concentrically arranged with respect to the northern and western sides of the structure. The unusual category of brittle deformation, the so-called 'shock deformation', observed in the collar strata has attracted worldwide attention over the past two decades. These deformation phenomena include the presence of coesite and stishovite, mylonites, and pseudotachylites, cataclasis at a microscopic scale, and the ubiquitous development of multiply striated joint surfaces (which include shatter cones, orthogonal, curviplanar, and conjugate fractures). The macroscopic to microscopic deformation features have led to the formulation of various hypotheses to account for the origin of the Vredefort structure: (1) tectonic hypotheses--deep crustal shear model, doming and N-directed thrust fault model, fold interference model, and diapir model; (2) the exogenous bolide impact hypothesis; and (3) the endogenous cryptoexplosion model.

Colliston, W. P.↗
NASA NTRS1991

The role of the gamma/gamma-prime eutectic and porosity on the tensile behavior of a single-crystal nickel-base superalloy

The microstructure of a single-crystal nickel-base superalloy, PWA 1480, has been varied by heat treatment and hot isostatic pressing in order to study the role of the gamma/gamma-prime eutectic and porosity on subsequent tensile behavior. The level of porosity was found not to affect any of the tensile properties, while the gamma/gamma-prime eutectic strongly influenced ductility. Eliminating the gamma/gamma-prime eutectic increased ductility which was attributed to the cleavage fracture of this constituent. It is proposed that such cleavage of the gamma/gamma-prime eutectic is initiated by the stress created from impinging slip bands, promoting shear localization, and final fracture along 111 slip planes. The precise nature of this fracture process is discussed, with emphasis on the role of the gamma/gamma-prime microstructure. The deformation structure of PWA 1480 was also studied, and while different in some respects from many other single-crystal superalloys, its fracture process appears to be similar.

Walston, W. S.↗
NASA NTRS1978

Investigation of the fracture mechanism of Ti-5Al-2.5Sn at cryogenic temperatures

Fractography and metallographic sectioning were used to investigate the influence of microstructure on the fracture mechanism and fracture toughness (KIC) of normal interstitial and extra low interstitial (ELI) Ti-5Al-25Sn at 20 K (-423 F) and 77 K (-320 F). Plates of each grade were mill annealed at 815 C followed by either air or furnace cooling. These variations in composition and cooling rate resulted in differences in the volume fraction and internal structure of the dispersed beta phase and in the ordering of the alpha matrix. The ELI alloys were tougher than the normal interstitial plates. KIC of the furnace-cooled ELI plate was 25% lower than that of the air-cooled ELI material. Variations in cooling rate had no influence of KIC of the normal interstitial alloys. Fractography showed that a large portion of the fracture surfaces were covered with elongated dimples. Metallographic sections of specimens deformed at 77 K showed that these features form at the intersections of slip bands or deformation twins with grain or twin boundaries. Ordering and higher interstitial levels increase the local strain in slip bands resulting in void nucleation at lower macroscopic strains and lower KIC values.

Van Stone, R. H.↗
NASA NTRS1985

Vibration characteristics of mistuned shrouded blade assemblies

An investigation of the mode localization phenomenon associated with mistuning is presented for shrouded blade assemblies. The calculations are based on a generic finite element model, which permits modeling of arbitrary mistuning and both slipping and nonslipping shroud interfaces. The results presented indicate that interactions occur between mistuning and slip effects, with maximum mode localization occurring when the shrouds slip freely. Certain modes are found to be very sensitive to shroud slip, and in some cases completely change character when slip occurs. Mode localization is most pronounced in the predominantly bending modes, and varies considerably from mode to mode. As the ratio of interblade coupling strength to mistuning strength is increased, the effect of mistuning is observed to decrease significantly. This result has important implications for the flutter problem, since it suggests that the stabilization effect available from mistuning is significantly less for a shrouded rotor as compared to an unshrouded rotor.

Bendiksen, O. O.↗
NASA NTRS1984

Focal depths and fault plane solutions of earthquakes and active tectonics of the Himalaya

Synthetic seismograms were compared with long-period body waves for nine earthquakes with epicenters in the Himalayan arc to determine depths of foci and to improve fault plane solutions. Focal depths are shallow (10-20 km). Inferred slip vectors are locally perpendicular to the mountain range; they plunge very gently (about 10 deg) in the eastern sections of the range and more steeply (about 25 deg) in western sections. Assuming India to be a rigid plate, the radially oriented slip vectors imply that southern Tibet extends at about half the rate of underthrusting in the Himalaya and therefore probably at about 5-10 mm/yr. The shallow depths and gentle dips of the fault planes, at least for the events in the eastern half of the range, are consistent with coherent underthrusting of the Indian plate beneath, at least, the Lesser Himalaya. The steeper dips of fault planes in the western part of the arc might reflect deformation of the overriding thrust plate or simply a steepening of the main underthrusting zone beneath the Greater Himalaya.

Baranowski, J.↗
NASA NTRS2010

A Geometric Approach to Modeling Microstructurally Small Fatigue Crack Formation: Simulation and Prediction of Crack Nucleation in AA 7075-T651 - 2

The objective of this paper is to develop further a framework for computationally modeling microstructurally small fatigue crack growth in AA 7075-T651 [1]. The focus is on the nucleation event, when a crack extends from within a second-phase particle into a surrounding grain, since this has been observed to be an initiating mechanism for fatigue crack growth in this alloy. It is hypothesized that nucleation can be predicted by computing a non-local nucleation metric near the crack front. The hypothesis is tested by employing a combination of experimentation and nite element modeling in which various slip-based and energy-based nucleation metrics are tested for validity, where each metric is derived from a continuum crystal plasticity formulation. To investigate each metric, a non-local procedure is developed for the calculation of nucleation metrics in the neighborhood of a crack front. Initially, an idealized baseline model consisting of a single grain containing a semi-ellipsoidal surface particle is studied to investigate the dependence of each nucleation metric on lattice orientation, number of load cycles, and non-local regularization method. This is followed by a comparison of experimental observations and computational results for microstructural models constructed by replicating the observed microstructural geometry near second-phase particles in fatigue specimens. It is found that orientation strongly influences the direction of slip localization and, as a result, in uences the nucleation mechanism. Also, the baseline models, replication models, and past experimental observation consistently suggest that a set of particular grain orientations is most likely to nucleate fatigue cracks. It is found that a continuum crystal plasticity model and a non-local nucleation metric can be used to predict the nucleation event in AA 7075-T651. However, nucleation metric threshold values that correspond to various nucleation governing mechanisms must be calibrated.

Hochhalter, Jake D.↗
NASA NTRS1983

The structure of evaporating and combusting sprays: Measurements and predictions

The structure of particle-laden jets and nonevaporating and evaporating sprays was measured in order to evaluate models of these processes. Three models are being evaluated: (1) a locally homogeneous flow model, where slip between the phases is neglected and the flow is assumed to be in local thermodynamic equilibrium; (2) a deterministic separated flow model, where slip and finite interphase transport rates are considered but effects of particle/drop dispersion by turbulence and effects of turbulence on interphase transport rates are ignored; and (3) a stochastic separated flow model, where effects of interphase slip, turbulent dispersion and turbulent fluctuations are considered using random sampling for turbulence properties in conjunction with random-walk computations for particle motion. All three models use a k-e-g turbulence model. All testing and data reduction are completed for the particle laden jets. Mean and fluctuating velocities of the continuous phase and mean mixture fraction were measured in the evaporating sprays.

Shuen, J. S.↗
NASA NTRS2000

The Plastic Flow Field in the Vicinity of the Pin-Tool During Friction Stir Welding

The plastic flow field in the vicinity of the pin-tool during Friction Stir Welding (FSW) needs to be understood if a theoretical understanding of the process is to be attained. The structure of welds does not exhibit the flow field itself, but consists in a residue of displacements left by the plastic flow field. The residue requires analysis to extract from it the instantaneous flow field around the pin-tool. A simplified merry-go-round model makes sense of some tracer experiments reported in the literature. A quantitative comparison is made of the displacements of copper wire markers with displacements computed from a hypothetical plastic flow field. The hypothetical plastic flow field consists in a circular rotation field about a translating pin tool with angular velocity varying with radius from the pin centerline. A sharply localized rotational field comprising slip on a surface around the tool agreed better with observations than a distributed slip field occupying a substantial volume around the tool. Both the tracer and the wire displacements support the "rotating plug" model, originally invoked or thermal reasons, of the FSW process.

Bernstein, E. L.↗
NASA NTRS1984

A theoretical and experimental study of turbulent nonevaporating sprays

Measurements and analysis limited to the dilute portions of turbulent nonevaporating sprays injected into a still air environment were completed. Mean and fluctuating velocities and Reynolds stress were measured in the continuous phase. Liquid phase measurements included liquid mass fluxes, drop sizes and drop size and velocity correlation. Initial conditions needed for model evaluation were measured at a location as close to the injector exit as possible. The test sprays showed significant effects of slip and turbulent dispersion of the discrete phase. The measurements were used to evaluate three typical models of these processes: (1) a locally homogenous flow (LHF) model, where slip between the phases were neglected; (2) a deterministic separated flow (DSF) model, where slip was considered but effects of drop dispersion by turbulence were ignored; and (3) a stochastic separated flow (SSF) model, where effects of interphase slip and turbulent dispersion were considered using random-walk computations for drop motion. The LHF and DSF models did not provide very satisfactory predictions for the present measurements. In contrast, the SSF model performed reasonably well with no modifications in the prescription of eddy properties from its original calibration. Some effects of drops on turbulence properties were observed near the dense regions of the sprays.

Solomon, A. S. P.↗
NASA NTRS1984

A theoretical and experimental study of turbulent evaporating sprays

Measurements and analysis limited to the dilute portions of turbulent evaporating sprays, injected into a still air environment were completed. Mean and fluctuating velocities and Reynolds stress were measured in the continuous phase. Liquid phase measurements included liquid mass fluxes, drop sizes and drop size and velocity correlation. Initial conditions needed for model evaluation were measured at a location as close to the injector exit as possible. The test sprays showed significant effects of slip and turbulent dispersion of the discrete phase. The measurements were used to evaluate three typical models of these processes: (1) a locally homogeneous flow (LHF) model, where slip between the phases were neglected; (2) a deterministic separated flow (DSF) model, where slip was considered but effects of drop dispersion by turbulence were ignored; and (3) a stochastic separated flow (SSF) model, where effects of interphase slip and turbulent dispersion were considered using random-walk computations for drop motion. For all three models, a k-epsilon model as used to find the properties of the continuous phase. The LHF and DSF models did not provide very satisfactory predictions for the present measurements. In contrast, the SSF model performed reasonably well--with no modifications in the prescription of eddy properties from its original calibration.

Solomon, A. S. P.↗