Methods of measuring residual stresses in components

Residual stresses occur in many manufactured structures and components. Large number of investigations have been carried out to study this phenomenon and its effect on the mechanical characteristics of these components. Over the years, different methods have been developed to measure residual stress for different types of components in order to obtain reliable assessment. The various specific methods have evolved over several decades and their practical applications have greatly benefited from the development of complementary technologies, notably in material cutting, full-field deformation measurement techniques, numerical methods and computing power. These complementary technologies have stimulated advances not only in measurement accuracy and reliability, but also in range of application; much greater detail in residual stresses measurement is now available. This paper aims to classify the different residual stresses measurement methods and to provide an overview of some of the recent advances in this area to help researchers on selecting their techniques among destructive, semi destructive and non destructive techniques depends on their application and the availabilities of those techniques. For each method scope, physical limitation, advantages and disadvantages are summarized. In the end this paper indicates some promising directions for future developments

Marshall Space Flight Center Research and Technology Report 2019

Today, our calling to explore is greater than ever before, and here at Marshall Space Flight Centerwe make human deep space exploration possible. A key goal for Artemis is demonstrating and perfecting capabilities on the Moon for technologies needed for humans to get to Mars. This years report features 10 of the Agencys 16 Technology Areas, and I am proud of Marshalls role in creating solutions for so many of these daunting technical challenges. Many of these projects will lead to sustainable in-space architecture for human space exploration that will allow us to travel to the Moon, on to Mars, and beyond. Others are developing new scientific instruments capable of providing an unprecedented glimpse into our universe. NASA has led the charge in space exploration for more than six decades, and through the Artemis program we will help build on our work in low Earth orbit and pave the way to the Moon and Mars. At Marshall, we leverage the skills and interest of the international community to conduct scientific research, develop and demonstrate technology, and train international crews to operate further from Earth for longer periods of time than ever before first at the lunar surface, then on to our next giant leap, human exploration of Mars. While each project in this report seeks to advance new technology and challenge conventions, it is important to recognize the diversity of activities and people supporting our mission. This report not only showcases the Centers capabilities and our partnerships, it also highlights the progress our people have achieved in the past year. These scientists, researchers and innovators are why Marshall and NASA will continue to be a leader in innovation, exploration, and discovery for years to come

Laser Beam Welding of Stainless Steels

Obiettivo principale di questa tesi di dottorato è quello di studiare la saldatura laser degli acciai inossidabili. Durante gli esperimenti un laser Nd-YAG in onda continua da 1.1kW è stato utilizzato per saldare rispettivamente acciai martensitici in configurazione di piena penetrazione e combinazioni di acciai austenitici/ferritici in configurazione d’angolo. È stata studiata l’influenza di vari parametri di processo come potenza del laser, velocità di saldatura, diametro della fibra, angolo di incidenza e defocalizzazione nonché le loro interazioni sulla geometria del giunto e sulle sue proprietà meccaniche. Si sono analizzati, inoltre, gli effetti della densità di energia e dell’energia per unità di lunghezza sulle caratteristiche del giunto di saldatura in modo da evidenziare la dipendenza del processo dai fenomeni di scambio termico. Successivamente si è studiato la microstruttura della solidificazione del giunto e la relativa distribuzione degli elementi di lega per diversi valori della densità di energia correlandole con la variazione locale della microdurezza. Durante il corso della ricerca, sono state utiliizzate tecniche di DOE come il FFD ed il RSM con l’obiettivo di modellare ed ottimizzare il processo di saldatura laser. In questa fase, per ogni materiale saldato sono stati elaborati dei modelli in grado di determinare i fattori chiave che governano il processo. Tali modelli, inoltre, sono stati ottimizzati prendendo in considerazione la combinazione dei parametri di processo che consente di avere giunti di qualità superiore in termin di geometria e caratteristiche meccaniche. È stato, infine, elaborato un modello teorico per la determinazione della geometria di un giunto ottenibile dalla saldatura in piena penetrazione di acciai ferritici. Tale modello si basa sul concetto che la geometria risultante è funzione del tipo di scambio termico che si genera durante il processo e che a sua volta tale scmbio termico vari in funzione della densità di energia fornita dla laser. Il modello ha dimostrato una corrispondenza con i dati sperimentali con una maggior accuratezza nel caso di saldatura per conduzione

Enhancement Material Removal Rate Optimization of Sinker EDM Process Parameters Using a Rectangular Graphite Electrode

This article discusses the optimization of sinker electrical discharge machining (sinker EDM) processes using SPHC material that has been hardened. The sinker EDM method is widely employed, for example, in the production of moulds, dies, and automotive and aeronautical components. There is neither contact nor a cutting force between the electrode and the   work material in sinker EDM. The disadvantage of the sinker EDM is its low material removal rate. This work aims to optimize the material removal rate (MRR) using graphene electrodes in a rectangular configuration. The SPHC material was selected to determine the optimum MRR model of the sinker EDM input parameter. The Taguchi experimental design was chosen. The Taguchi technique used three input parameters and three experimental levels. Pulse current (I), spark on time (Ton), and gap voltage were among the input parameters (Vg). The graphite rectangle was chosen as an electrode material. The input parameter effect was evaluated by S/N ratio analysis. The result showed that pulse current has the most significant impact on material removal rate in the initial study, followed by spark on time and gap voltage. All input parameters are directly proportional to the MRR. For optimal material removal rate, the third level of pulse current, spark on time, and gap voltage must be maintained. In addition, the proposed Taguchi optimization model could be applied to an existing workshop floor as a simple and practical electronic tool for predicting wear and future research

Ultrasonic Spot Welding of Dissimilar Metal Sheets: An Experimental, Numerical and Metallurgical Investigation

Ultrasonic metal welding (USMW) is a new and emerging concept used in the industries over the past twenty years and serving to the manufacturing sectors like aviation, medical, microelectronics, automotive and much more due to various hurdles faced by conventional fusion welding process. USMW is a clean and reliable technique in which the welding takes place with a high energy, no flux or filler metal needed, longer tool life and it takes very short time (less than one second) to weld materials in a perfect controllable environment with greater efficiency.To acquire high vibration amplitude in USMW, there is a necessity to design a welding system that consists of components like a booster and horn. The principal purpose of these parts is to amplify the input amplitude of vibration so that the energy transferred to the welding spot should be sufficient for creating a joint. In the present study, new type of booster and horn are proposed and modelled with adequate precision not only to produce high-quality welds but also to solve a lot of issues faced while designing these types of ultrasonic tools. The modal analysis module of finite element method (FEM) is used to analyze the effects of different step lengths and fillet radius on its natural frequency of 20 kHz, ensuring that these components will be in a resonating condition with other parts of the system. It is found that there were 1.11 % and 2.52 % errors in the length calculation of both parts. Similarly, 0.61 % error is obtained for both while calculating the magnification ratio. However, such low levels of errors may be considered to be insignificant. The dynamic analysis has also been performed to find out the stress distribution in both parts under cyclic loading conditions. Due to these cyclic loading conditions, the nodal regions (hot areas) are under highly stressed, and the relevant temperature field is consequently determined. The results obtained from the simulation, and experimental results were found to be close to each other and an error of 2% was noticed. Other welding components are also fabricated such as anvil, specimen-holder and backing plate for producing a satisfactory weld. Meanwhile, the complex mechanism behind the USMW has been addressed and modelled analytically. This model can predict the forces as well as temperatures those occur during the welding process and also explains the effects of various material properties and surface conditions on the weld behaviour. The experiments have been performed on the aluminium, copper, brass and stainless steel metal sheets with a number of different configurations, anvil designs, and surface conditions. The fundamental aspect of this study is to control the process parameters like vibration amplitude, weld pressure and weld time so that, an appreciable weld strength can be obtained. Thus, tensile shear and T-peel failure load studies suggest that increase in vibration amplitude means the increase of scrubbing action between the faying surfaces, resulting a better bonding strength. Similarly, increase in weld pressure also increases these weld failure loads and reach a peak value at a particular pressure. But, subsequently, these failure loads decrease due to suppression of relative motion between sheets and initiation of cracks. Excessive weld time also causes cracks around the weld spot. Likewise, if the thickness of the sheets increased, weld strengths are also increased due to absorption of more amount of ultrasonic energy. Moreover, the highest weld interface temperatures and weld areas are observed at the end of weld time because of the larger plastic deformation at the mating surfaces. For all the experiments, first anvil design shows maximum failure loads due to its non-cutting width and angle of knurls. Likewise, on the increase of surface roughness, the tensile shear, and T-peel failure loads decrease. It is found that, in lubricating condition, the highest failure loads are obtained. Furthermore, the polynomial regression, artificial neural network (ANN) and adaptive neuro-fuzzy inference system (ANFIS) methods are developed and compared for each performance measure so that the whole welding process can be accurately described by a best predictive model. A welding mechanics based numerical model has been developed which can predict the temperatures during USMW process for various surface conditions. For all the experimental investigations, the predictive results show good agreement with the experimental values. In addition to it, acoustic softening during ultrasonic welding is found to very significant for the reduction in yield strength of the weld material up to 95 %. It is seen that the quality of welding depends on the material properties, process parameters, and thickness of the workpiece. The present investigation also explains in details the effect of process parameters on the responses through metallurgical analysis. A quality lobe of welding like “under weld”, “good weld” and “over weld” is proposed after observing the fractured samples in optical microscopy and scanning electron microscopy (SEM). Meantime, energy dispersive spectroscopy (EDS) and X- ray diffraction (XRD) analyses are also used to reveal the thickness of interatomic diffusion and IMCs along the weld interface

Optimization of Activated Tungsten Inert Gas welding process parameters using heat transfer search algorithm: with experimental validation using case studies

The Activated Tungsten Inert Gas welding (A-TIG) technique is characterized by its capability to impart enhanced penetration in single pass welding. Weld bead shape achieved by A-TIG welding has a major part in deciding the final quality of the weld. Various machining variables influence the weld bead shape and hence an optimum combination of machining variables is of utmost importance. The current study has reported the optimization of machining variables of A-TIG welding technique by integrating Response Surface Methodology (RSM) with an innovative Heat Transfer Search (HTS) optimization algorithm, particularly for attaining full penetration in 6 mm thick carbon steels. Welding current, length of the arc and torch travel speed were selected as input process parameters, whereas penetration depth, depth-to-width ratio, heat input and width of the heat-affected zone were considered as output variables for the investigations. Using the experimental data, statistical models were generated for the response characteristics. Four different case studies, simulating the real-time fabrication problem, were considered and the optimization was carried out using HTS. Validation tests were also carried out for these case studies and 3D surface plots were generated to confirm the effectiveness of the HTS algorithm. It was found that the HTS algorithm effectively optimized the process parameters and negligible errors were observed when predicted and experimental values compared. HTS algorithm is a parameter-less optimization technique and hence it is easy to implement with higher effectiveness

Aeronautical Engineering: A continuing bibliography, supplement 120

This bibliography contains abstracts for 297 reports, articles, and other documents introduced into the NASA scientific and technical information system in February 1980

NASA SBIR abstracts of 1990 phase 1 projects

The research objectives of the 280 projects placed under contract in the National Aeronautics and Space Administration (NASA) 1990 Small Business Innovation Research (SBIR) Phase 1 program are described. The basic document consists of edited, non-proprietary abstracts of the winning proposals submitted by small businesses in response to NASA's 1990 SBIR Phase 1 Program Solicitation. The abstracts are presented under the 15 technical topics within which Phase 1 proposals were solicited. Each project was assigned a sequential identifying number from 001 to 280, in order of its appearance in the body of the report. The document also includes Appendixes to provide additional information about the SBIR program and permit cross-reference in the 1990 Phase 1 projects by company name, location by state, principal investigator, NASA field center responsible for management of each project, and NASA contract number

Development of a multi-objective optimization algorithm based on lichtenberg figures

This doctoral dissertation presents the most important concepts of multi-objective optimization and a systematic review of the most cited articles in the last years of this subject in mechanical engineering. The State of the Art shows a trend towards the use of metaheuristics and the use of a posteriori decision-making techniques to solve engineering problems. This fact increases the demand for algorithms, which compete to deliver the most accurate answers at the lowest possible computational cost. In this context, a new hybrid multi-objective metaheuristic inspired by lightning and Linchtenberg Figures is proposed. The Multi-objective Lichtenberg Algorithm (MOLA) is tested using complex test functions and explicit contrainted engineering problems and compared with other metaheuristics. MOLA outperformed the most used algorithms in the literature: NSGA-II, MOPSO, MOEA/D, MOGWO, and MOGOA. After initial validation, it was applied to two complex and impossible to be analytically evaluated problems. The first was a design case: the multi-objective optimization of CFRP isogrid tubes using the finite element method. The optimizations were made considering two methodologies: i) using a metamodel, and ii) the finite element updating. The last proved to be the best methodology, finding solutions that reduced at least 45.69% of the mass, 18.4% of the instability coefficient, 61.76% of the Tsai-Wu failure index and increased by at least 52.57% the natural frequency. In the second application, MOLA was internally modified and associated with feature selection techniques to become the Multi-objective Sensor Selection and Placement Optimization based on the Lichtenberg Algorithm (MOSSPOLA), an unprecedented Sensor Placement Optimization (SPO) algorithm that maximizes the acquired modal response and minimizes the number of sensors for any structure. Although this is a structural health monitoring principle, it has never been done before. MOSSPOLA was applied to a real helicopter’s main rotor blade using the 7 best-known metrics in SPO. Pareto fronts and sensor configurations were unprecedentedly generated and compared. Better sensor distributions were associated with higher hypervolume and the algorithm found a sensor configuration for each sensor number and metric, including one with 100% accuracy in identifying delamination considering triaxial modal displacements, minimum number of sensors, and noise for all blade sections.Esta tese de doutorado traz os conceitos mais importantes de otimização multi-objetivo e uma revisão sistemática dos artigos mais citados nos últimos anos deste tema em engenharia mecânica. O estado da arte mostra uma tendência no uso de meta-heurísticas e de técnicas de tomada de decisão a posteriori para resolver problemas de engenharia. Este fato aumenta a demanda sobre os algoritmos, que competem para entregar respostas mais precisas com o menor custo computacional possível. Nesse contexto, é proposta uma nova meta-heurística híbrida multi-objetivo inspirada em raios e Figuras de Lichtenberg. O Algoritmo de Lichtenberg Multi-objetivo (MOLA) é testado e comparado com outras metaheurísticas usando funções de teste complexas e problemas restritos e explícitos de engenharia. Ele superou os algoritmos mais utilizados na literatura: NSGA-II, MOPSO, MOEA/D, MOGWO e MOGOA. Após validação, foi aplicado em dois problemas complexos e impossíveis de serem analiticamente otimizados. O primeiro foi um caso de projeto: otimização multi-objetivo de tubos isogrid CFRP usando o método dos elementos finitos. As otimizações foram feitas considerando duas metodologias: i) usando um meta-modelo, e ii) atualização por elementos finitos. A última provou ser a melhor metodologia, encontrando soluções que reduziram pelo menos 45,69% da massa, 18,4% do coeficiente de instabilidade, 61,76% do TW e aumentaram em pelo menos 52,57% a frequência natural. Na segunda aplicação, MOLA foi modificado internamente e associado a técnicas de feature selection para se tornar o Seleção e Alocação ótima de Sensores Multi-objetivo baseado no Algoritmo de Lichtenberg (MOSSPOLA), um algoritmo inédito de Otimização de Posicionamento de Sensores (SPO) que maximiza a resposta modal adquirida e minimiza o número de sensores para qualquer estrutura. Embora isto seja um princípio de Monitoramento da Saúde Estrutural, nunca foi feito antes. O MOSSPOLA foi aplicado na pá do rotor principal de um helicóptero real usando as 7 métricas mais conhecidas em SPO. Frentes de Pareto e configurações de sensores foram ineditamente geradas e comparadas. Melhores distribuições de sensores foram associadas a um alto hipervolume e o algoritmo encontrou uma configuração de sensor para cada número de sensores e métrica, incluindo uma com 100% de precisão na identificação de delaminação considerando deslocamentos modais triaxiais, número mínimo de sensores e ruído para todas as seções da lâmina