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High Magnification Surface Topography Based Digital Image Correlation (Dic) For Identifying Damage Accumulation And Crack Growth In Polycrystalline Nickel, Arash Valiollahi

Mechanical and Aerospace Engineering Dissertations

Damage index parameters that have been formulated to identify damage localization in plastically deformed materials typically require all six stress or strain components. Recently, simulations through Crystal Plasticity Finite Element Method (CPFEM) have been widely used to extract damage initiation parameters. However, these models are rarely verified due to the challenges in measuring the out-of-plane deformation/strain experimentally. A damage index combining the effective plastic strain and surface roughness change is investigated for identifying damage accumulation sites and predicting crack propagation path in polycrystalline pure Nickel. A novel Digital Image Correlation (DIC) technique is developed to measure both in-plane and out-of-plane …

Fatigue Performance Modeling In Advanced Out-Of-Autoclave Composites For Aerospace Applications, Grayson Reid Curry

Mechanical and Aerospace Engineering Theses

Increased application of composite materials in the military and civil applications renewed the interest to development of high-fidelity methodologies for predicting their performance characteristics. Besides the traditional autoclave processed structural composites such as IM7/8552 and IM7/977-3 widely used on various platforms, novel materials such IM7/5320-1 suitable for Out-of-Autoclave (OoA) cure became of interest. Static and fatigue performance prediction of Open-Hole quasi-isotropic laminates made from IM7/5320-1 was performed in this work by using the Finite Element Analysis software BSAM. Progressive failure simulation including delaminations, matrix cracks and fiber failure was performed. Regularized eXtended Finite Element Methods (RXFEM) was used for mesh …

The Role Of Slip System Activation On Ni-Based Superalloy High Temperature Fatigue, Alexandru Lopazan

Doctoral Dissertations and Master's Theses

Nickel-based superalloys are used extensively in the aviation industry, particularly in aircraft engine components. These materials are desirable due to their high strength, resistance to creep, corrosive environment, and high temperature. It has been well documented that material fatigue is characterized by material microstructure, type of loading, and other parameters. Currently, research into the effects of fatigue on complex materials like nickel-based superalloys is being pursued. Previous research has found that preconditioning of Inconel 718 samples at 700 ℃ with 1.0% strain led to an improved fatigue life. It has been suggested that this could be caused by the activation …

Characterization Of Fatigue Strength Of Additively Manufactured Ti-6al-4v With Recoater Blade Interference Flaws And Residual Stresses Towards An Enhanced Fatigue Substantiation Methodology For Aerospace Structures Applications, Joshua Manyara Mochache

Mechanical and Aerospace Engineering Dissertations

This research characterized the fatigue strength of additively manufactured (AM) Ti-6Al-4V, through fatigue and static tests conducted using specimens with and without recoater blade interference flaws (RBIF), and thus further enhanced the fatigue substantiation methodology for AM parts by using combined fatigue strength knock-down-factors (KDF) developed from this study. Qualification and certification (Q&C) of metallic AM parts, through acceptable methods for fatigue and damage tolerance (F&DT) substantiation, is an area where significant gaps still exist. While progress has been made in design as well as materials and process standardization, Q&C of additively manufactured metallic structural parts, especially those in civil …

Prediction Of Solder Joint Fatigue Life Of Photonic Package Using ?-? Materials, Ojas Tyagi

Mechanical and Aerospace Engineering Theses

Fatigue life prediction has become very important factor in reliability of any electronic components to withstand extreme thermal stresses in industrial standard. Hence, photonic packages are widely used in telecommunication and computer applications. The primary focus of this study is to determine the thermal cycles to crack initiation of solder bump used in laser array waferboard for telecommunication applications. This includes GaAs Laser chip on waferboard and Si substrate with pure Indium solder balls in between. Indium has proved higher fatigue life in various experimental studies in the field of reliability and lead-free material. Therefore, a solder ball was designed …

Characterization And Enhancement Of Fatigue And Fracture Properties In Thermoplastic Fff Parts Using In-Situ Annealing, Manjarik Mrinal

Mechanical and Aerospace Engineering Dissertations

Fused filament fabrication (FFF) show high anisotropy and reduced mechanical properties as compared to conventional manufacturing techniques. This happens due to the poor interlaminar bonding between the layers, as a result of premature halt of bond healing process. Previous research works show multiple approaches to improve the bond quality to enhance the mechanical properties of FFF parts, however these are complex and expensive techniques. In this work a novel print head assembly is presented to offer a simple and effective solution by applying a thermal field to the part as it is being printed to preheat the previously deposited layer, …

Effect Of Cold Work Expansion On The Fatigue Life Of Pre-Cracked Al 2024-T3, Christopher Leirer

Doctoral Dissertations and Master's Theses

No abstract provided.

Thermal / Structural Analysis Of The Hb 650 Thermal Shield, Gerald J. Smith

Graduate Research Theses & Dissertations

Fermilab’s PIP-II project’s superconducting linear accelerator (Linac) will drive the next generation of particle accelerators through a revolution in beam intensity. Key to beam intensification are the high efficiencies of niobium-tin superconducting radiofrequency (SRF) cavities operating at cryogenic temperatures near 5 Kelvin. A multifaceted approach is employed to achieve and maintain the extreme temperature. Vacuum provides the first barrier to thermal convection. Physical thermal intercept zones further isolate the exterior shell vacuum vessel at 300 Kelvin from the supercooled beamline. The first thermal intercept lies just inside the exterior vacuum vessel forming the 40 Kelvin zone. This 40K thermal shield …

Estimation Of The Fatigue Life Of Additively Manufactured Metallic Components Using Modified Strain Life Parameters Based On Surface Roughness, Peter Grohs

Masters Theses

In this study, a method is developed to estimate the effects of surface roughness on the fatigue life of additively manufactured titanium Ti6Al4V, aluminum 7075–T6, and steel 4340 alloys through modified strain life parameters using finite element analysis (FEA). This method is highly beneficial to the fatigue analysis of as-built additively manufactured metal components, which possess rough surfaces that reduce fatigue life significantly but are challenging to analyze directly using finite element simulation because of complex geometries, i.e., modeling an exact surface profile is arduous.

An effective stress concentration factor, incorporating roughness data, is defined to quantify their effects on …

An Analytical Design Of Experiments Method For Fatigue Constrained Design Optimization Of A 3d Printed Structure, Ashish Pokharel

Mechanical and Aerospace Engineering Theses

A design of experiments approach has been used to analytically determine a low cycle fatigue (LCF) constraint for use in design optimization of 3D printed structures. In context of metal additive manufacturing, the process of melting, solidification and consolidation of metal powder introduces very high temperature gradient field within the build which in turn results in high compressive stresses at the core and tensile stresses at the outer surface of the part after it has cooled down to room temperature post build. An approach of finite element modeling in ANSYS Additive has been used to develop a residual stress profile …

Determination Of Chemical Notch, KChem On Aluminum And Steel When Subjected Under Slow Strain Rate Test In Corrosive Environment, Joshua Teo Lee Kuok

Masters Theses

When designing for any mechanical components or system, the question would arise as to how the material would react to the loads subjected on it? Would the component survive its service load? How would it react to environmental corrosion? To answer these questions, the technique used in this thesis paper is the Slow Strain Rate Test (SSRT) method. Aluminum and steel were chosen as the material to be tested in this paper. Al 7075-T651, and Al 6061-T651 was chosen due to its wide range of application, high strength to weight ratio and ease of machinability. It is highly used in …

The Effect Of Task Load, Automation Reliability, And Environment Complexity On Uav Supervisory Control Performance, Sarah M. Sherwood

Doctoral Dissertations and Master's Theses

Over the last decade, military unmanned aerial vehicles (UAVs) have experienced exponential growth and now comprise over 40% of military aircraft. However, since most military UAVs require multiple operators (usually an air vehicle operator, payload operator, and mission commander), the proliferation of UAVs has created a manpower burden within the U.S. military. Fortunately, simultaneous advances in UAV automation have enabled a switch from direct control to supervisory control; future UAV operators will no longer directly control a single UAV subsystem but, rather, will control multiple advanced, highly autonomous UAVs. However, research is needed to better understand operator performance in a …

Optimum Design Of Composite Wing Spar Subjected To Fatigue Loadings, Juan Reuben Lazarin

Master's Theses

Composites are now being incorporated into aircraft designs because of their high strength to weight ratio compared to traditional metal materials. Due to the complexity of the material, composite parts are presently being over designed to satisfy static and fatigue requirements. A greater understanding of composite fatigue behavior will allow for even greater weight savings leading to increased fuel economy. A critical part of an aircraft that is subjected to fatigue bending loads are its wings. The forces acting on the wings include its lift distribution, powerplant, and fuel which can be carried in the wing body. When in flight …

Mechanism Of Shot Peening Enhancement For The Fatigue Performance Of Aa7050-T7451, Daniel James Chadwick

Open Access Theses

Shot peening is a dynamic cold working process involving the impingement of peening media onto a substrate surface. Shot peening is commonly employed as a surface treatment technique within the aerospace industry during manufacturing, in order to improve fatigue performance of structural components. The compressive residual stress induced during shot peening is understood to result in fatigue crack growth retardation, improving the performance of shot peened components. However, shot peening is a compromise between the benefit of inducing a compressive residual stress and causing detrimental surface damage. Due to the relatively soft nature of AA7050-T7451, shot peening can result in …

Dynamic Monitoring And Life Prediction Of Internal Strain-Gage Balances, David Leon Yoder

Masters Theses

Wind tunnel test customers continue to push the limits by producing air vehicle designs that produce high aerodynamic loads at the desired test conditions. These loads are a combination of steady aerodynamic, unsteady aerodynamic, and inertial forces. A methodology to monitor the health of a wind tunnel strain-gage balance has been developed. The objective of this methodology is to define the stress limits of the balance and monitor these limits so the balance can be safely tested without failure of the balance. A balance failure could result in costly damage to the wind tunnel model, support system, and the wind …

Modeling Of Environmentally Assisted Fatigue Crack Growth Behavior, Sree Phani Chandar Reddy

Dissertations

The formation of fatigue cracks and their propagation due to cyclic loading in metals have been a concern for more than hundred years. Since fatigue failure were first reported by the railroad industry in 1840s, tremendous progress has been achieved in understanding fatigue behavior of metals. But fatigue damage is still a concern due to its complex dependency on various environmental variable like humidity, temperature, time and corrosive environment. Although numerous theories and models have been proposed in the past, the effects of environment on fatigue crack growth (FCG) is not completely understood. This dissertation aims to shed light on …

Fatigue Testing And Data Analysis Of Welded Steel Cruciform Joints, Alina Shrestha

University of New Orleans Theses and Dissertations

In this study, ABS Publication 115, “Guidance on Fatigue Assessment of Offshore Structures” is briefly reviewed. Emphasis is on the S-N curves based fatigue assessment approach of non-tubular joints, and both size and environment effects are also considered. Further, fatigue tests are performed to study the fatigue strength of load-carrying and non-load-carrying steel cruciform joints that represent typical joint types in marine structures. The experimental results are then compared against ABS fatigue assessment methods, based on nominal stress approach, which demonstrates a need for better fatigue evaluation parameter. A good fatigue parameter by definition should be consistent and should correlate …

Assessing Variability In Microstructural Influence On Fatigue Crack Growth Behavior, Matthew James Durbin

Open Access Theses

The effect of microstructural variability has long been recognized as a major contributing factor in the scatter of published fatigue data. It is also acknowledged that these effects are generally more prevalent for short cracks and in the threshold region. A number of models exist to explain individual microstructural effects such as grain boundary influence, grain cluster, average grain size, porosity etc. It is the aim of the Aeronautics and Astronautics Fatigue Lab to develop an encompassing model that accurately predicts these effects.

In order to develop this model a range of material data will be required to inform and …

Static And Fatigue Failure Response Of Woven Carbon Fiber Specimens With Double Edge Notches, Ahmad J. Amini

Master's Theses

Carbon fiber composites are continually seeing increased use in aerospace applications. It is necessary to understand their failure modes in order to properly design and perform analysis on structures constructed primarily from them. This thesis studies woven carbon fiber composites with and without double-edge notches in a series of static and fatigue tests performed on an Instron 8801 servo-hydraulic testing system.

Specimens were constructed of Advanced Composites Group product # LTM45EL woven carbon fiber pre-preg/epoxy and were cut to approximately 9-inch in length and 1-inch in width. Notches were cut into some of the specimens using a slitting saw blade …

Fatigue Behavior Of An Advanced Sic/Sic Composite At Elevated Temperature In Air And In Steam, Devon T. Christensen

Theses and Dissertations

The fatigue behavior of an advanced Silicon Carbide/Silicon Carbide (SiC/SiC) ceramic matrix composite (CMC) was investigated at 1200 ˚C in laboratory air and in steam environments. The composite consisted of a SiC matrix reinforced with Boron Nitride (BN) coated Hi-Nicalon fibers woven into eight-harness-satin (8HS) weave plies. Tensile stress-strain behavior and tensile properties were also evaluated at 1200 ˚C. Tension-tension fatigue tests were conducted in both laboratory air and in steam at 1200 ˚C at frequencies of 0.1 Hz, 1.0 Hz, and 10 Hz. The tension-tension fatigue tests had a ratio of minimum stress to maximum stress of R = …

Effects Of Delamination On Composite Sandwich Structures Under Static And Fatigue Loading, Eugene Everett Eswonia

Master's Theses

This thesis will present the experimental and numerical analysis of composite sandwich structures under monotonic and fatigue loading. The sandwich skins were made of fiberglass and the core used was a closed cell PVC foam. Initial delaminations were introduced into the sandwich structures during manufacturing to see the effect of delamination size on the ultimate strength and monotonic fracture. Fiberglass rods, called shear keys, added to the foam core to determine whether or not they increased the strength of the test specimens. Furthermore, shear key locations were also varied and their effects noted. The fixed rate static behavior for all …

Nonlinear Response And Fatigue Estimation Of Aerospace Curved Surface Panels To Acoustic And Thermal Loads, Adam Przekop

Mechanical & Aerospace Engineering Theses & Dissertations

This work presents a finite element modal formulation for large amplitude free vibration of arbitrary laminated composite shallow shells. The system equations of motion are formulated first in the physical structural-node degrees of freedom (DOF). Then, the system is transformed into general Duffing-type modal equations with modal amplitudes of coupled linear bending-inplane modes. The linear bending-inplane coupling is due to the shell curvature as well as unsymmetric lamination stacking. Multiple modes, inplane inertia, and the first-order transverse shear deformation for composites are considered in the formulation. A triangular shallow shell finite element is developed from an extension of the triangular …

Nonlinear Response And Fatigue Estimation Of Surface Panels To White And Non-White Gaussian Random Excitations, Jean-Michel Dhainaut

Mechanical & Aerospace Engineering Theses & Dissertations

In stochastic structural dynamics, the majority of analyses have dealt with linear structures under stationary, Gaussian, and band-limited white noise excitations. Although these simplifying assumptions may be justified, in many processes experimental data have shown quite frequently the non-stationary and non-Gaussian characteristics of the loads. An efficient finite element modal formulation has recently been developed to extend the analysis to nonlinear structural responses. Laminated plate theory and von Karman large displacement relations are used to derive the nonlinear equations of motion for an arbitrarily laminated composite panel subjected to combined acoustic and thermal loads. The nonlinear equations of motion in …

Classification Of In-Flight Fatigue Cracks In Aircraft Structures Using Acoustic Emission And Neural Networks, Christopher Lee Rovik

Master's Theses - Daytona Beach

The research encompassed within this paper deals with the analysis and classification of fatigue cracks in aircraft structures. The particular structure that was examined was the vertical tail section of a Cessna T-303 Crusader aircraft. The analysis was performed using the nondestructive evaluation technique known as acoustic emission (AE), as well as the artificial intelligence of neural networks. Data were taken in a controlled laboratory environment as well as in a flying testbed aboard the aircraft.

The first part of the research involved the analysis of a typical aircraft structure in a controlled laboratory environment. This support structure was fabricated …

In-Flight Fatigue Crack Monitoring Of An Aircraft Engine Cowling, Samuel Gordon Vaughn Iii

Master's Theses - Daytona Beach

This research investigates the feasibility of implementing an in-flight fatigue crack monitoring system in an airplane to identify fatigue crack growth. An acoustic emission data acquisition system coupled with a Kohonen self organizing map neural network were used to perform the analysis.

Fatigue cracking was responsible for ripping the top of a fuselage off an Aloha Airlines Boeing 737-200 as it carried passengers over the Pacific Ocean, killing some aboard. This tragedy is perhaps a precursor of problems to come, as our nation’s aircraft age. These planes experience fatigue as they perform their daily routine of ferrying passengers from location …

Detection Of Fatigue Crack Growth In A Simulated Aircraft Fuselage, Michael Lee Marsden

Master's Theses - Daytona Beach

Acoustic emission (AE) nondestructive testing can detect fatigue cracks as they occur in complex structures. One use for AE has been in-flight detection of fatigue cracks in aircraft. The KC-135 aircraft were successfully monitored as early as 1979. The main problem with this and subsequent applications was an unfavorable signal to noise ratio, the key being to separate the small amplitude crack signals from the large amplitude ambient noise. This was accomplished here through the use of a Kohonen self-organizing map (SOM) neural network.

In order to simulate a fuselage undergoing fatigue, a pressure vessel was constructed from a 0.040 …

Finite Element Frequency Domain Solution Of Nonlinear Panel Flutter With Temperature Effects And Fatigue Life Analysis, David Yongxiang Xue

Mechanical & Aerospace Engineering Theses & Dissertations

A frequency domain solution method for nonlinear panel flutter with thermal effects using a consistent finite element formulation has been developed. The von Karman nonlinear strain-displacement relation is used to account for large deflections, the quasi-steady first-order piston theory is employed for aerodynamic loading and the quasi-steady thermal stress theory is applied for the thermal stresses with a given change of the temperature distribution, ΔΤ (x, y, z). The equation of motion under a combined thermal-aerodynamic loading can be mathematically separated into two equations and then solved in sequence: (1) thermal-aerodynamic postbuckling and (2) limit-cycle oscillation. The Newton-Raphson iteration technique …