The First International Conference for Smart Systems and Robotics in Space and Medicine

A viewgraph presentation describing smart systems and robotics in space and medicine is shown. The topics include: 1) NASA Applications; and 2) Laboratory Data

Effects of Different R ratios on Fatigue Crack Growth in Laser Peened Friction Stir Welds

The influence of laser peening on the fatigue crack growth behavior of friction stir welded (FSW) Aluminum Alloy (AA) 7075-T7351 sheets was investigated. The surface modification resulting from the peening process on the fatigue crack growth of FSW was assessed for two different R ratios. The investigation indicated a significant decrease in fatigue crack growth rates resulting from using laser shock peening compared with unpeened, welded and unwelded specimens. The slower fatigue crack growth rate was attributed to the compressive residual stresses induced by the peening

Characterization of Electron Beam Free-Form Fabricated 2219 Aluminum and 316 Stainless Steel

Researchers at NASA Langley Research Center have developed an additive manufacturing technology for ground and future space based applications. The electron beam free form fabrication (EBF3) is a rapid metal fabrication process that utilizes an electron beam gun in a vacuum environment to replicate a CAD drawing of a part. The electron beam gun creates a molten pool on a metal substrate, and translates with respect to the substrate to deposit metal in designated regions through a layer additive process. Prior to demonstration and certification of a final EBF3 part for space flight, it is imperative to conduct a series of materials validation and verification tests on the ground in order to evaluate mechanical and microstructural properties of the EBF3 manufactured parts. Part geometries of EBF3 2219 aluminum and 316 stainless steel specimens were metallographically inspected, and tested for strength, fatigue crack growth, and fracture toughness. Upon comparing the results to conventionally welded material, 2219 aluminum in the as fabricated condition demonstrated a 30% and 16% decrease in fracture toughness and ductility, respectively. The strength properties of the 316 stainless steel material in the as deposited condition were comparable to annealed stainless steel alloys. Future fatigue crack growth tests will integrate various stress ranges and maximum to minimum stress ratios needed to fully characterize EBF3 manufactured specimens

Verification of shrinkage curvature code prediction models

An attempt is made to theoretically and experimentally verify the shrinkage curvature models presented in Eurocode 2 and BS 8110. These codes claim that the models originally derived and proven for uncracked sections are suitable, with modification, for predicting the behaviour of cracked sections, although this claim has never been proven experimentally. To achieve verification, an alternative theoretical approach is initially proposed in this paper. In this theoretical model, the effect of shrinkage, creep and the variation in the neutral axis position of the section are taken into account. The stresses developed in the steel and concrete at a cracked section according to this theoretical model are then applied to a finite-element (FE) model representing a portion of the beam from the crack to mid-way between the crack and an adjacent crack. Ultimately, the mean curvature is determined. Experimentally, pairs of beams were cast and subjected to a level of flexural loading to produce a stabilised crack pattern in the constant-moment zone. The behaviour of the beams was monitored for up to 180 days. For any pair of beams, one beam was cast using a high-shrinkage concrete and the other with a low-shrinkage concrete. Each concrete type, however, exhibits similar creep. Therefore, shrinkage curvature can be obtained by subtracting the long-term movements of one beam from the other. These experimentally defined curvatures were compared with the mean curvatures obtained from the FE analysis. The comparison showed reasonable agreement. The curvatures were also compared with uncracked and cracked curvatures predicted by the codes. The curvatures derived in this investigation fell within the boundaries of the uncracked and cracked curvatures predicted by the codes and, for the fully cracked case, the curvatures were closer to the uncracked boundary

Fatigue Crack Growth in Peened Friction Stir Welds

Friction stir welding induces residual stresses that accelerates fatigue crack growth in the weld nugget. Shot peening over the weld had little effect on growth rate. Laser peening over the weld retarded the growth rate: Final crack growth rate was comparable to the base, un-welded material. Crack tunneling evident from residual compressive stresses. 2195-T8 fracture surfaces were highly textured. Texturing makes comparisons difficult as the material system is affecting the data as much as the processing. Material usage becoming more common in space applications requiring additional work to develop useful datasets for damage tolerance analyses

7075-T6 and 2024-T351 Aluminum Alloy Fatigue Crack Growth Rate Data

Experimental test procedures for the development of fatigue crack growth rate data has been standardized by the American Society for Testing and Materials. Over the past 30 years several gradual changes have been made to the standard without rigorous assessment of the affect these changes have on the precision or variability of the data generated. Therefore, the ASTM committee on fatigue crack growth has initiated an international round robin test program to assess the precision and variability of test results generated using the standard E647-00. Crack growth rate data presented in this report, in support of the ASTM roundrobin, shows excellent precision and repeatability

Composite Overwrapped Pressure Vessels, A Primer

Due to the extensive amount of detailed information that has been published on composite overwrapped pressure vessels (COPVs), this document has been written to serve as a primer for those who desire an elementary knowledge of COPVs and the factors affecting composite safety. In this application, the word "composite" simply refers to a matrix of continuous fibers contained within a resin and wrapped over a pressure barrier to form a vessel for gas or liquid containment. COPVs are currently used at NASA to contain high pressure fluids in propulsion, science experiments, and life support applications. They have a significant weight advantage over all metal vessels but require unique design, manufacturing, and test requirements. COPVs also involve a much more complex mechanical understanding due to the interplay between the composite overwrap and the inner liner. A metallic liner is typically used in a COPV as a fluid permeation barrier. The liner design concepts and requirements have been borrowed from all-metal vessels. However, application of metallic vessel design standards to a very thin liner is not straightforward. Different failure modes exist for COPVs than for all-metal vessels, and understanding of these failure modes is at a much more rudimentary level than for metal vessels

Elastic Plastic Fracture Analysis of an Aluminum COPV Liner

Onboard any space-launch vehicle, composite over-wrapped pressure vessels (COPVs) may be utilized by propulsion or environmental control systems. The failure of a COPV has the potential to be catastrophic, resulting in the loss of vehicle, crew or mission. The latest COPV designs have reduced the wall-thickness of the metallic liner to the point where the material strains plastically during operation. At this time, the only method to determine the damage tolerance lifetime (safe-life) of a plastically responding metallic liner is through full-scale COPV testing. Conducting tests costs substantially more and can be far more time consuming than performing an analysis. As a result of this cost, there is a need to establish a qualifying process through the use of a crack growth analysis tool. This paper will discuss fracture analyses of plastically responding metallic liners in COPVs. Uni-axial strain tests have been completed on laboratory specimens to collect elastic-plastic crack growth data. This data has been modeled with the crack growth analysis tool, NASGRO 6.20 to predict the response of laboratory specimens and subsequently the complexity of a COPV

Damage Tolerance Analysis of a Pressurized Liquid Oxygen Tank

A damage tolerance assessment was conducted of an 8,000 gallon pressurized Liquid Oxygen (LOX) tank. The LOX tank is constructed of a stainless steel pressure vessel enclosed by a thermal-insulating vacuum jacket. The vessel is pressurized to 2,250 psi with gaseous nitrogen resulting in both thermal and pressure stresses on the tank wall. Finite element analyses were performed on the tank to characterize the stresses from operation. Engineering material data was found from both the construction of the tank and the technical literature. An initial damage state was assumed based on records of a nondestructive inspection performed on the tank. The damage tolerance analyses were conducted using the NASGRO computer code. This paper contains the assumptions, and justifications, made for the input parameters to the damage tolerance analyses and the results of the damage tolerance analyses with a discussion on the operational safety of the LOX tank

Time-dependent behaviour of cracked, partially bonded reinforced concrete beams under repeated and sustained loads

This paper compares the flexural behaviour of cracked partially bonded (in the mid-span, maximum moment zone) reinforced concrete beams subjected to (i) static sustained load and (ii) static sustained with cyclically repeating load. Information relating to surface strains and mid-span deflections were continuously recorded for a period of 90 days. The sustained load level represented that which produced the stabilized crack pattern. The amplitude of the superimposed cyclic load was considered to be a small fraction of the sustained load. The experimental outcome shows that under sustained load alone, the long-term mid-span deflection of reinforced concrete beams with artificially debonded reinforcement is substantially higher than that of normally bonded equivalent beams. For the cyclically exerted load addition there was no substantial difference between the observed ultimate deformations of bonded and debonded beams. Nonlinear finite element software (Midas FEA) was used to simulate these results and it was found that a numerical-experimental match can be achieved after applying necessary modifications to the distribution of shrinkage down through the beams’ cross-section