Monolithic ceramic analysis using the SCARE program

The Structural Ceramics Analysis and Reliability Evaluation (SCARE) computer program calculates the fast fracture reliability of monolithic ceramic components. The code is a post-processor to the MSC/NASTRAN general purpose finite element program. The SCARE program automatically accepts the MSC/NASTRAN output necessary to compute reliability. This includes element stresses, temperatures, volumes, and areas. The SCARE program computes two-parameter Weibull strength distributions from input fracture data for both volume and surface flaws. The distributions can then be used to calculate the reliability of geometrically complex components subjected to multiaxial stress states. Several fracture criteria and flaw types are available for selection by the user, including out-of-plane crack extension theories. The theoretical basis for the reliability calculations was proposed by Batdorf. These models combine linear elastic fracture mechanics (LEFM) with Weibull statistics to provide a mechanistic failure criterion. Other fracture theories included in SCARE are the normal stress averaging technique and the principle of independent action. The objective of this presentation is to summarize these theories, including their limitations and advantages, and to provide a general description of the SCARE program, along with example problems

Simplified cyclic structural analyses of SSME turbine blades

Anisotropic high-temperature alloys are used to meet the safety and durability requirements of turbine blades for high-pressure turbopumps in reusable space propulsion systems. The applicability to anisotropic components of a simplified inelastic structural analysis procedure developed at the NASA Lewis Research Center is assessed. The procedure uses as input the history of the total strain at the critical crack initiation location computed from elastic finite-element analyses. Cyclic heat transfer and structural analyses are performed for the first stage high-pressure fuel turbopump blade of the space shuttle main engine. The blade alloy is directionally solidified MAR-M 246 (nickel base). The analyses are based on a typical test stand engine cycle. Stress-strain histories for the airfoil critical location are computed using both the MARC nonlinear finite-element computer code and the simplified procedure. Additional cases are analyzed in which the material yield strength is arbitrarily reduced to increase the plastic strains and, therefore, the severity of the problem. Good agreement is shown between the predicted stress-strain solutions from the two methods. The simplified analysis uses about 0.02 percent (5 percent with the required elastic finite-element analyses) of the CPU time used by the nonlinear finite element analysis

Cyclic structural analyses of anisotropic turbine blades for reusable space propulsion systems

Turbine blades for reusable space propulsion systems are subject to severe thermomechanical loading cycles that result in large inelastic strains and very short lives. These components require the use of anisotropic high-temperature alloys to meet the safety and durability requirements of such systems. To assess the effects on blade life of material anisotropy, cyclic structural analyses are being performed for the first stage high-pressure fuel turbopump blade of the space shuttle main engine. The blade alloy is directionally solidified MAR-M 246 alloy. The analyses are based on a typical test stand engine cycle. Stress-strain histories at the airfoil critical location are computed using the MARC nonlinear finite-element computer code. The MARC solutions are compared to cyclic response predictions from a simplified structural analysis procedure developed at the NASA Lewis Research Center

Fracture mechanics concepts in reliability analysis of monolithic ceramics

Basic design concepts for high-performance, monolithic ceramic structural components are addressed. The design of brittle ceramics differs from that of ductile metals because of the inability of ceramic materials to redistribute high local stresses caused by inherent flaws. Random flaw size and orientation requires that a probabilistic analysis be performed in order to determine component reliability. The current trend in probabilistic analysis is to combine linear elastic fracture mechanics concepts with the two parameter Weibull distribution function to predict component reliability under multiaxial stress states. Nondestructive evaluation supports this analytical effort by supplying data during verification testing. It can also help to determine statistical parameters which describe the material strength variation, in particular the material threshold strength (the third Weibull parameter), which in the past was often taken as zero for simplicity

Analysis of whisker-toughened ceramic components: A design engineer's viewpoint

The use of ceramics components in gas turbines, cutting tools, and heat exchangers has been limited by the relatively low flaw tolerance of monolithic ceramics. The development of whisker toughened ceramic composites offers the potential for considerable improvement in fracture toughness as well as strength. However, the variability of strength is still too high for the application of deterministic design approaches. Several phenomenological reliability theories proposed for this material system are reviewed and the development is reported of a public domain computer algorithm. This algorithm, when coupled with a general purpose finite element program, predicts the fast fracture reliability of a structural component under multiaxial loading conditions

Ceramics Analysis and Reliability Evaluation of Structures (CARES). Users and programmers manual

This manual describes how to use the Ceramics Analysis and Reliability Evaluation of Structures (CARES) computer program. The primary function of the code is to calculate the fast fracture reliability or failure probability of macroscopically isotropic ceramic components. These components may be subjected to complex thermomechanical loadings, such as those found in heat engine applications. The program uses results from MSC/NASTRAN or ANSYS finite element analysis programs to evaluate component reliability due to inherent surface and/or volume type flaws. CARES utilizes the Batdorf model and the two-parameter Weibull cumulative distribution function to describe the effect of multiaxial stress states on material strength. The principle of independent action (PIA) and the Weibull normal stress averaging models are also included. Weibull material strength parameters, the Batdorf crack density coefficient, and other related statistical quantities are estimated from four-point bend bar or unifrom uniaxial tensile specimen fracture strength data. Parameter estimation can be performed for single or multiple failure modes by using the least-square analysis or the maximum likelihood method. Kolmogorov-Smirnov and Anderson-Darling goodness-of-fit tests, ninety percent confidence intervals on the Weibull parameters, and Kanofsky-Srinivasan ninety percent confidence band values are also provided. The probabilistic fast-fracture theories used in CARES, along with the input and output for CARES, are described. Example problems to demonstrate various feature of the program are also included. This manual describes the MSC/NASTRAN version of the CARES program

Design of ceramic components with the NASA/CARES computer program

The ceramics analysis and reliability evaluation of structures (CARES) computer program is described. The primary function of the code is to calculate the fast-fracture reliability or failure probability of macro-scopically isotropic ceramic components. These components may be subjected to complex thermomechanical loadings, such as those found in heat engine applications. CARES uses results from MSC/NASTRAN or ANSYS finite-element analysis programs to evaluate how inherent surface and/or volume type flaws component reliability. CARES utilizes the Batdorf model and the two-parameter Weibull cumulative distribution function to describe the effects of multiaxial stress states on material strength. The principle of independent action (PIA) and the Weibull normal stress averaging models are also included. Weibull material strength parameters, the Batdorf crack density coefficient, and other related statistical quantities are estimated from four-point bend bar or uniform uniaxial tensile specimen fracture strength data. Parameter estimation can be performed for a single or multiple failure modes by using a least-squares analysis or a maximum likelihood method. Kolmogorov-Smirnov and Anderson-Darling goodness-to-fit-tests, 90 percent confidence intervals on the Weibull parameters, and Kanofsky-Srinivasan 90 percent confidence band values are also provided. Examples are provided to illustrate the various features of CARES

Reliability analysis of a structural ceramic combustion chamber

The Weibull modulus, fracture toughness and thermal properties of a silicon nitride material used to make a gas turbine combustor were experimentally measured. The location and nature of failure origins resulting from bend tests were determined with fractographic analysis. The measured Weibull parameters were used along with thermal and stress analysis to determine failure probabilities of the combustor with the CARES design code. The effect of data censoring, FEM mesh refinement, and fracture criterion were considered in the analysis

Noninteractive Macroscopic Reliability Model for Ceramic Matrix Composites With Orthotropic Material Symmetry

A macroscopic noninteractive reliability model for ceramic matrix composites is presented. The model is multiaxial and applicable to composites that can be characterized as orthotropic. Tensorial invariant theory is used to create an integrity basis with invariants that correspond to physical mechanisms related to fracture. This integrity basis is then used to construct a failure funciton per unit volume (or area) of material. It is assumed that the overall strength of the composite is governed by weakest link theory. This leads to a Weibull type model similar in nature to the principle of independent action (PIA) model for isotropic monolithic ceramics. An experimental program to obtain model parameters is briefly discussed. In addition, qualitative features of the model are illustrated by presenting reliability surfaces for various model parameters

Composite Nanomechanics: A Mechanistic Properties Prediction

A unique mechanistic theory is described to predict the properties of nanocomposites. The theory is based on composite micromechanics with progressive substructuring down to a nanoscale slice of a nanofiber where all the governing equations are formulated. These equations have been programmed in a computer code. That computer code is used to predict 25 properties of a mononanofiber laminate. The results are presented graphically and discussed with respect to their practical significance. Most of the results show smooth distributions. Results for matrix-dependent properties show bimodal through-the-thickness distribution with discontinuous changes from mode to mode