VTechWorks Repository :: Browsing by Author "Duke, John C. Jr."

Browsing by Author "Duke, John C. Jr."

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Acousto-Ultrasonic Evaluation of Cyclic Fatigue of Spot Welded Structures
Gero, Brian Matthew III (Virginia Tech, 1997-08-28)
An acousto-ultrasonic approach is used to explore the damage development in tensile shear spot welds during fatigue loading. There is reasonable data to support the hypothesis that a decrease in an AU signal is indicative of the presence of an internal crack and could be used for monitoring and evaluation purposes.
Application of a Fabry-Perot interferometer for measuring machining forces in turning operations
Hansbrough, Andrew K. (Virginia Tech, 1993-05-05)
The FP interferometer was found to be feasible for detecting changes in machining forces. The fiber optic sensor was able to detect increases in strain corresponding to force increases detected by a dynamometer. The FP interferometer system must progress in several ways. A better data acquisition and data analysis system must be developed. A robust sensor must be made to withstand the harsh environment of machining. Also a method for eliminating the affects of thermal strain must be created. Finally, the placement of the FP sensor must also be determined. The FP has the potential to effectively monitor machining forces without affecting the rigidity of a turning operation setup.
Assessment of Commercial Corrosion Inhibiting Admixtures for Reinforced Concrete
Brown, Michael Carey (Virginia Tech, 1999-11-11)
Corrosion of reinforcing steel in concrete exposed to chloride-laden environments is a well-known and documented phenomenon. The need for cost effective systems for protection against corrosion has become increasingly clear since the first observations of severe corrosion damage to interstate bridges in the 1960's. As one potential solution to the mounting problem of corrosion deterioration of structures, corrosion-inhibiting admixtures have been researched and introduced into service. This report conveys the results of a three-part laboratory study of corrosion inhibiting admixtures in concrete. The commercial corrosion inhibiting admixtures for concrete have been analyzed by three evaluation methods, including: • Conventional concrete corrosion cell prisms under ponding, • Black steel reinforcing bars immersed in simulated concrete pore solutions, • Electrochemical screening tests of special carbon steel specimens in electrochemical corrosion cells containing filtered cement slurry solution. The purposes of the study include: • Determining the influence of a series of commercially available corrosion inhibiting admixtures on general concrete handling, performance and durability properties not related to corrosion. • Determining the effectiveness of corrosion inhibiting admixtures for reduction or prevention of corrosion of reinforcing steel in concrete, relative to untreated systems, under laboratory conditions. • Conducting a short-term pore solution immersion test for inhibitor performance and relating the results to those of the more conventional long-term corrosion monitoring techniques that employ admixtures in reinforced concrete prisms. • Determining whether instantaneous electrochemical techniques can be applied in screening potential inhibitor admixtures. Concrete properties under test included air content, slump, heat of hydration, compressive strength, and electrical indication of chloride permeability. Monitoring of concrete prism specimens included macro-cell corrosion current, mixed-cell corrosion activity as indicated by linear polarization, and ancillary temperature, relative humidity, and chloride concentration documentation. Simulated pore solution specimens were analyzed on the basis of weight loss and surface area corroded as a function of chloride exposure. Electrochemical screening involved polarization resistance of steel in solution. Results include corrosion potential, polarization resistance and corrosion current density.
Assessment of Infrared Thermography for NDE of FRP Bridge Decks
Miceli, Marybeth (Virginia Tech, 2000-12-11)
Statistics released in the fall 1989 showed that 238,357 (41%) of the nation's 577,710 bridges are either structurally deficient or functionally obsolete. New materials, such as fiber reinforced polymeric composites (FRP), are being suggested for use in bridge systems to solve some of the current problems. These materials are thought to be less affected by corrosive environmental conditions than conventional civil engineering materials. Therefore they may require less maintenance and provide longer life spans. More specifically, glass fiber reinforced vinyl ester matrix composites are considered possible replacements for deteriorating conventional bridge decks due to their durability, decreased weight, and relative affordability. In order to facilitate rapid acceptance of FRP structural components into the world of civil structural engineering, effective and efficient NDE techniques must be explored and documented in these situations. This thesis will discuss the use of Infrared Thermography (IRT) as a means of detecting debonds and voids caused by conditions encountered both in fabrication and in the field. As forced convective hot air is applied within the bridge deck, debonds between bridge deck components near the riding surface appear cold while imperfections near the bottom of the deck give rise to concentrations of heat. These variations in thermal propagation patterns are observed by the infrared camera and indicate possible structural deficiencies. Results of experimentation and thermal analyses from laboratory studies of a model bridge deck and some from in situ full-scale investigations are presented.
Automated Characterization of Bridge Deck Distress Using Pattern Recognition Analysis of Ground Penetrating Radar Data
Scott, Michael L. (Virginia Tech, 1999-08-02)
Many problems are involved with inspecting and evaluating the condition of bridges in the United States. Concrete bridge deck inspection and evaluation presents one of the largest problems. The deterioration of these concrete decks progresses more rapidly than any other bridge component, which leads to early concrete deck replacements that must be done before the bridge superstructure needs to be replaced. The primary cause of deterioration in these concrete bridge decks is corrosion-induced concrete cracking, which frequently results in delaminations. Delamination distress increases the life cycle cost of maintaining a concrete bridge deck, particularly when it is not detected early on. Early detection of delamination distress can facilitate economical repair and rehabilitation work, but bridge engineers must recommend deck replacement if repairs are delayed too long or inspection tools cannot detect delaminations early enough. The Federal Highway Administration has responded to the need for a better bridge deck inspection tool by contracting Lawrence Livermore National Laboratory to develop two new prototype ground penetrating radar systems. These two systems generate three-dimensional data that provide a representation of features that lie below the bridge deck surface. Both of these systems produce large amounts of data for an individual bridge deck, which makes automated data processing very desirable. The primary goal of the automated processing is to characterize bridge deck distress represented in the data. This study presents data collected from sample bridge deck sections using one of the prototype systems. It also describes the development and implementation of appropriate methods for automating data processing. The automated data processing is accomplished using image processing and pattern recognition algorithms developed in the study.
Carbon fiber surface treatments for improved adhesion to thermoplastic polymers
DeVilbiss, Thomas Alexander (Virginia Polytechnic Institute and State University, 1987)
The effect of anodization in NaOH, H₂SO₄, and amine salts on the surface chemistry of carbon fibers was examined by x-ray photoelectron spectroscopy (XPS). The surfaces of carbon fibers after anodization in NaOH and H₂SO₄ were examined by scanning transmission electron microscopy (STEM). angular dependent XPS, ultraviolet (UV) absorption spectroscopy of the anodization bath, secondary ion mass spectrometry, and polar/dispersive surface energy analysis. Hercules AS-4, Dexter Hysol XAS, and Union Carbide T-300 fibers were examined by STEM, angular dependent XPS, and breaking strength measurement before and after commercial surface treatment. The fibers from the three companies were anodized to create similar surface chemistry on each fiber. XPS was used to compare the surface chemistry after anodization. Adhesion of carbon fibers to polysulfone, polycarbonate, and polyetherimide was studied using the fiber critical length test. Oxygen and nitrogen were added to the fiber surfaces by anodization in amine salts. Analysis of the plasmon peak in the carbon 1s signal indicated that H₂SO₄ anodization affected the morphological structure of the carbon fiber surface. UV absorption spectra of the anodization bath, SIMS, and angular dependent XPS indicate that NaOH anodization removes amorphous carbon from the fiber. The oxygen and nitrogen content on the fiber surfaces were affected by commercial surface treatment. The Union Carbide fiber had much lower oxygen content after laboratory anodization than the Hercules or Dexter Hysol fibers. The breaking strength of all three fibers was increased by anodization. Laboratory anodization resulted in better fiber/matrix adhesion than the commercial surface treatment for the Hercules and Dexter Hysol fibers. Fiber/matrix adhesion was better for the commercially treated Union Carbide fiber than for the laboratory treated fiber. The work of adhesion of carbon fibers to thermoplastic resins was calculated using the geometric mean relationship. A correlation was observed between the dispersive component of the work of adhesion and the interfacial adhesion.
Characterization and deterioration detection of Portland cement concrete using electromagnetic waves over a wideband of frequency
Haddad, Rami H. (Virginia Tech, 1996-01-05)
An experimental program was conducted to establish a better understanding of the effect of Portland cement concrete's (PCC' s) basic properties on its dielectric properties over a wideband of frequency (0.1 MHz-10 GHz). Other parameters that may influence measured dielectric properties were investigated. These include chlorides presence in PCC, deterioration (due to alkali silica reaction [ASR] and freezing and thawing [Fff] damage), delamination, and segregation. In addition, the effect of different sizes of delaminated areas (filled with water) was evaluated using measured dielectric properties and waveform amplitude. Three different electromagnetic wave (EM) setups were used to conduct those measurements: parallel plate capacitor (0.1-40 MHz), coaxial transmission line (100 MHz to 1 GHz), and TEM antenna (0.5-10 GHz). The setups were designed and built by engineers from the Civil and Electrical Engineering Departments at Virginia Tech as a part of the overall research study. Testing results indicated the feasibility of using EM to detect changes in the basic properties of PCC over low RF using the parallel plate capacitor. This included the effect of curing time, water to cement (w/c) ratio, aggregate type, cement type, and air entrainment. The effect of curing time on the complex dielectric constant of PCC was quantitatively determined. However, the success in detecting changes in the PCC basic properties was limited at the microwave frequency range of 100 MHz to 10 GHz. Changes in the complex dielectric constant due to chloride intrusion into PCC were quantitatively significant only over the low radio wave frequency. The ASR in PCC was successfully identified by measured complex dielectric constant over the low RF, especially less than 20 MHz. Insignificant changes in the complex dielectric constant over the frequency range of 0.1 MHz to 1 GHz was noted when PCC was exposed to FIT cycles. Complex dielectric constant and waveform amplitude measurements of pce slabs over frequency range of 1 to 10 GHz showed significant changes with water content (in PCC); due to further hydration or injecting of water into empty delaminated areas. Waveform amplitude showed significant sensitivity to delamination and chlorides and low sensitivity to segregation. After testing several mixture theories to identify the most appropriate theory that is capable of predicting the dielectric constant of PCC (based on the dielectric properties of its components), Bruggemenn mixture theory was found to be the most feasible.
Characterization and deterioration detection of portland cement concrete using ultrasonic waves
Al-Akhras, Nabil M. (Virginia Tech, 1995-11-10)
An experimental study was conducted to characterize Portland cement concrete (PCC), to detect deterioration induced by freeze/thaw and alkali-silica reaction, and to detect chloride presence in PCC using ultrasonic waves. The experimental program was initiated to investigate the effect of water to cement (w/c) ratio, aggregate type, and air entrainn1ent on measured ultrasonic wave velocity and signal energy. Three w/c ratios (0.35, 0.45, and 0.55) were evaluated. Two aggregate types, quartzite and limestone, were included in the PCC mixes separately. Mixes were prepared as non-air entrained and air entrained. Thus, a total of twelve batches were prepared to evaluate PCC using ultrasonic waves at two frequencies, 54 and 340 kHz. The experimental program to investigate freeze/thaw (FT) damage included the effect of curing time, w/c ratio, and aggregate type. The effect of curing time was investigated by exposing PCC specimens cured for 3 and 7 days to FT. Two w/c ratios were considered, 0.45 and 0.55. The effect of aggregate on detecting FT damage was investigated using two types of crushed stone aggregate, quartzite and limestone. Alkali-silica reaction (ASR) damage was investigated uSIng two w/c ratios, 0.35 and 0.45. Embedded composite strain gages were used to monitor the ASR deleterious deterioration. High alkali cement and active silica aggregate were used to produce ASR.
Characterization of high temperature creep in siliconized silicon carbide using ultrasonic techniques
Buttram, Jonathan D. (Virginia Tech, 1990-04-04)
Ultrasonic velocity and attenuation were both measured on samples containing various degrees of damage due to high temperature creep. These results were compared with parameters associated with creep damage such as strain and cavity formation, in order to better understand the mechanisms of creep in Si/SiC and to determine if ultrasonics can be used in evaluating the severity of damage. The data indicated that both ultrasonic velocity and attenuation are directly related to creep strain and can be used in evaluating creep damage. Ultrasonic velocity was found to be exponentially related to creep strain. Cavity formation was found not to significantly affect either of the measured ultrasonic properties. The results indicated that Si/SiC behaves as a two phase material in that high frequency ultrasound propagates primarily through the silicon carbide phase and not by the silicon phase.
Closure integrity testing of heat sealed aseptic packaging using scanning acoustic microscopy
Jarrosson, Bruno P. (Virginia Tech, 1992-02-11)
The objective of this study was to determine the possible application of ultrasonic inspection for non-destructive, online evaluation of the integrity of heat sealed, flexible package structure commonly used in packaging of aseptic and shelf-stable food products. A scanning acoustic microscope (SAM), Olympus UH-3, and image analysis system were used to establish the operational parameters to ultrasonically inspect the heat seal closure of various flexible packages. The frequency range, attenuation, and focal length (Z-value) were determined respectively for paper laminate containers, plastic and plastic/aluminum pouches and plastic trays with plastic or plastic/aluminum lidding materials. The SAM images of channel leakers, blisters and wrinkles were sufficiently characteristic to allow their identification. The same should be possible in an on-line, ultrasonic testing device through proper design of the transducers and scanning mechanism of the inspection system and by monitoring of the ultrasonic signal. Channel leakers of 20 μm diameter were successfully detected in all package structures with the exception of the paper laminate which scattered the ultrasonic waves. The frequency used for inspection ranged from 30 to 100 MHz and best results were obtained when focussing at the seal bottom surface. As a general rule, lower frequencies were used for inspection of relatively thick seals or laminates containing an aluminum layer. Geometry, thickness, surface characteristics, and laminate composition of the seal to be inspected were found to affect SAM's performance. The SAM was able to detect defects as small as 20 μm when working in the pulse mode, using focussed transducers of frequency ranging between 30 and 100 MHz. However, because smaller defects could not technically be manufactured at the seal interface, this value is not definite and it is believed that smaller defects could be successfully detected, especially in the higher frequency range. For optimum results, seals to be inspected should be free of embossment, flat, and should remain parallel to the surface of the transducer during inspection. Finally, biotests showed that a 20 μm channel leaker in a seal of 5 mm width was of sufficient size to cause post-process contamination in Meal Ready to Eat (MRE, plastics/AI structure) pouches.
Computerized Ultrasonic Raytracing Model for C-scans of Solid Steel Bridge Pins
Parikh, Sanjiv D. (Virginia Tech, 1998-08-06)
This report describes the results of computerized ultrasonic C-scanning of solid steel bridge pins using a raytrace model. The raytrace model was developed to facilitate interpretation of data obtained from an ultrasonic C-scanning system for the Virginia Transportation Research Council (VTRC). The report discusses the reasons behind the development of the raytrace model, as well as specifications of the model, the input conditions, and the data output and visualization. The model uses as input, various "boundary" conditions of the solid steel pin with reduced diameter pin ends, as well as size and location information of a flaw or a wear groove placed within the main pin body. The model considers sound beams to be composed of rays and calculates ray reflections/conversions. This is done until the ray returns to a receiver location or is lost due to exceeding the time-of-flight. Once the model has returned with the received ray data, it uses the receiver conditions provided (transducer used, size of scanning grid, grid resolution, etc.), and calculates a 2-Dimensional C-scan image for each particular depth/time selected. Using PV-Wave visualization software, it is possible to plot the values for each depth to view a color graph. This graphical plot can then be analyzed/compared with the field C-scans to determine the closest match of a flaw or a wear groove inside the bridge pin. This helps in deciding if the condition of the pin is acceptable.
Detection of fiber fracture in Unidirectional Fiber Reinforced Composites using an In-Plane Fiber Optic Sensor
Cassino, Christopher Daniel (Virginia Tech, 2002-04-26)
Fiber reinforced polymers (FRP) are an efficient and inexpensive method of repairing deteriorating infrastructure. FRP sheets can be applied to spalling bridge sections and columns to prevent further deterioration and increase stiffness. However, the effect of the environment on the long-term durability of FRP and how the various damage mechanisms initiate and develop are not known. Systems for structural health monitoring are being sought as a means of managing important components in transportation systems as assets in light of modern life cycle cost concepts. This study characterizes a fiber optic sensor for use in detecting acoustic emissions (AE) in FRP. The results of AE analysis (signal amplitude, frequency spectra, MARSE, and in-plane displacement) caused by simulated fiber fracture experiments and other types of mechanical loading in FRP test coupons are reported. The applications to the development of FRP structural health monitoring systems are also discussed.
Determination of Crispness in Breaded Fried Chicken Nuggets Using Ultrasonic Technique
Antonova, Irina (Virginia Tech, 2001-12-18)
Crispness is one of the most important and desirable textural characteristics that signify freshness and high quality in breaded fried foods. Though many approaches to instrumental measurement of crispness have been made, the best measurements are still inconclusive. There is no reliable method available that can accurately measure and quantify crispness in breaded fried foods. In this study, the mechanical and ultrasonic techniques were used to determine crispness in breaded fried chicken nuggets under different storage conditions. The mechanical measurements have been made, using an Instron universal testing machine. An ultrasonic non-destructive evaluation system was used to measure ultrasonic properties of breaded friend chicken nuggets. A pair of dry-coupling 250-kHz ultrasonic transducers was used to perform the ultrasonic transmission through the breaded fried chicken nugget. The equipment set up was in the through-transmission mode because breaded fried chicken nugget is highly attenuative material. A sensory panel of eight members was trained to evaluate crispness in breaded fried foods. Panelists rated crispness on a nine-point category scale (1 = not crisp/soggy, 9 = very crisp). Sensory crispness values for breaded fried foods under different storage conditions were obtained. Ultrasonic velocity, transmission loss, peak frequencies and its energies, peak force and total energy were determined for each tested product. Correlation between sensory crispness and instrumental parameters suggests that the ultrasonic method can be used to evaluate crispness. The ultrasonic velocity had high correlation with sensory crispness (R2 = 0.83). This indicates that sensory crispness could be reasonably well predicted by the ultrasonic velocity.
Determining the Air Void Parameters of Concrete Using Digital Image Analysis of Polarized Light Micrographs
Scott, Michael L. (Virginia Tech, 1997-04-22)
The ASTM C457 test has long been a standard used to obtain the air void parameters of concrete materials. These air void parameters provide valuable information that has been linked to the performance of concrete under conditions such as freezing and thawing cycles. The standard test procedure involves linearly traversing a cut and polished section of a concrete specimen while a technician observes it under a microscope. Chord lengths of material constituents that the technician observes along the linear traverse are recorded and later used to calculate air void parameters statistically. This procedure is long and tedious, which makes it susceptible to human error due to operator fatigue. This study proposes and implements a new test method for evaluating concrete air void parameters using an image analysis method. A polishing procedure along with a differential interference contrast microscope are used to obtain high contrast images of material constituents, which provide raw data for the image analysis method. Because of the high contrast that can be obtained, cement paste, air voids in the cement paste, and aggregate materials in the concrete can be distinguished from one another based on these images. An image analysis program has been written for this study which linearly traverses these images and records the chord lengths of material constituents in a similar way to the standard ASTM C457 test. The chord length data must be processed further, however, because features in the images can be truncated by the edge of the image. Correction calculations for this problem are implemented in the image analysis algorithm. Two specimens which have been previously tested using the standard ASTM C457 method by the Virginia Transportation Research Council, (VTRC), are used in this study. The air void parameters obtained using the new test are compared directly with the results obtained by VTRC for the two specimens. Statistical comparisons indicate that the results of the new test are indeed significant, showing the potential it has for practical implementation. There are drawbacks to the test including a long polishing procedure, but this process can be automated. The new test appears to have excellent potential for practical application, but it should be emphasized that the test has only been implemented using materials in two concrete specimens. Further study on a variety of other concrete materials would be required for implementation in a standard procedure.
The development of an interpretive methodology for the application of real-time acousto-ultrasonic NDE technique for monitoring damage in ceramic composites under dynamic loads
Tiwari, Anil (Virginia Tech, 1993)
Research effort was directed towards developing a near real-time, acousto-ultrasonic (AU), nondestructive evaluation (NDE) tool to study the failure mechanisms of ceramic composites. Progression of damage is monitored in real-time by observing the changes in the received AU signal during the actual test. During the real-time AU test, the AU signals are generated and received by the AU transducers attached to the specimen while it is being subjected to increasing quasi-static loads or cyclic loads (10 Hz, R = 0.1). The received AU signals for 64 successive pulses were gated in the time domain (T = 40.96 µsec) and then averaged every second over ten load cycles and stored in a computer file during fatigue tests. These averaged gated signals are representative of the damage state of the specimen at that point of its fatigue life. This is also the first major attempt in the development and application of real-time AU for continuously monitoring damage accumulation during fatigue without interrupting the test. The present work has verified the capability of the AU technique to assess the damage state in silicon carbide/calcium aluminosilicate (SiC/CAS) and silicon carbide/magnesium aluminosilicate (SiC/MAS) ceramic composites. Continuous monitoring of damage initiation and progression under quasi-static ramp loading in tension to failure of unidirectional and cross-ply SiC/CAS and quasi-isotropic SiC/MAS ceramic composite specimens at room temperature was accomplished using near real-time AU parameters. The AU technique was shown to be able to detect the stress levels for the onset and saturation of matrix cracks, respectively. The critical cracking stress level is used as a design stress for brittle matrix composites operating at elevated temperatures. The AU technique has found that the critical cracking stress level is 10-15 % below the level presently obtained for design purposes from analytical models. An acousto-ultrasonic stress-strain response (AUSSR) model for unidirectional and cross-ply ceramic composites was formulated. The AUSSR model predicts the strain response to increasing stress levels using real-time AU data and classical laminated plate theory. The Weibull parameters of the AUSSR model are used to calculate the design stress for thermo-structural applications. Real-time AU together with the AUSSR model was used to study the failure mechanisms of SiC/CAS ceramic composites under static and fatigue loading. An S-N curve was generated for a cross-ply SiC/CAS ceramic composite material. The AU results are corroborated and complemented by other NDE techniques, namely, in-situ optical microscope video recordings and edge replication.
A direct on-line ultrasonic sensing method to determine tool and process conditions during turning operations
Nayfeh, Taysir H. (Virginia Tech, 1993)
Machining operations in automated manufacturing centers are under-performing by 20-80%. Optimizing these machining operations requires on-line knowledge about the cutting tool's condition and the process state. Currently, this information is either not reliable or not available in a timely manner. This is due to the lack of suitable sensors, which must measure on-line directly and accurately one or more of the relevant tool and process information sources in the hostile machining environment. A direct, active, ultrasonic method for on-line sensing of the tool condition and process state in turning operations was developed. Sensing is achieved by using an ultrasonic transducer operating at 10 MHz in a pulse-echo mode to send pulses through the tool. The amplitude and propagation time of the reflected pulses are modulated by the tool nose, flank, temperature, and by the material in contact with the tool. The reflected pulses are received and processed by a high speed digital signal processing system. This method has the potential to directly and accurately measure on-line several relevant processes and cutting tool parameters through the use of a single sensor. These parameters are tool-workpiece contact, tool wear, tool chipping, temperature and chatter.
The Effects of Load Ratio on Threshold Fatigue Crack Growth of Aluminum Alloys
Newman, John Andrew (Virginia Tech, 2000-10-17)
The integrity of nearly all engineering structures are threatened by the presence of cracks. Structural failure occurs if a crack larger than a critical size exists. Although most well designed structures initially contain no critical cracks, subcritical cracks can grow to failure under fatigue loading, called fatigue crack growth (FCG). Because it is impossible or impractical to prevent subcritical crack growth in most applications, a damage tolerant design philosophy was developed for crack sensitive structures. Design engineers have taken advantage of the FCG threshold concept to design for long fatigue lives. FCG threshold (DKth) is a value of DK (crack-tip loading), below which no significant FCG occurs. Cracks are tolerated if DK is less than DKth. However, FCG threshold is not constant. Many variables influence DKth including microstructure, environment, and load ratio. The current research focuses on load ratio effects on DKth and threshold FCG. Two categories of load ratio effects are studied here: extrinsic and intrinsic. Extrinsic load ratio effects operate in the crack wake and include fatigue crack closure mechanisms. Intrinsic load ratio effects operate in the crack-tip process zone and include microcracking and void production. To gain a better understanding of threshold FCG load ratio effects (1) a fatigue crack closure model is developed to consider the most likely closure mechanisms at threshold, simultaneously, and (2) intrinsic load ratio mechanisms are identified and modeled. An analytical fatigue crack closure model is developed that includes the three closure mechanisms considered most important at threshold (PICC, RICC, and OICC). Crack meandering and a limited amount of mixed-mode loading are also considered. The rough crack geometry, approximated as a two-dimensional sawtooth wave, results in a mixed-mode crack-tip stress state. Dislocation and continuum mechanics concepts are used to determine mixed-mode crack face displacements. Plasticity induced crack closure is included by modifying an existing analytical model, and an oxide layer in the crack mouth is modeled as a uniform layer. Finite element results were used to verify the analytical solutions for crack-tip stress intensity factor and crack face displacements. These results indicate that closure for rough cracks can occur at two locations: (1) at the crack-tip, and (2) at the asperity nearest the crack-tip. Both tip contact and asperity contact must be considered for rough cracks. Tip contact is more likely for high Kmax levels, thick oxide layers, and shallow asperity angles, a. Model results indicate that closure mechanisms combine in a synergistic manner. That is, when multiple closure mechanisms are active, the total closure level is greater than the sum of individual mechanisms acting alone. To better understand fatigue crack closure where multiple closure mechanisms are active (i.e. FCG threshold), these interactions must be considered. Model results are well supported by experimental data over a wide range of DK, including FCG threshold. Closure-free load ratio effects were studied for aluminum alloys 2024, 7050, and 8009. Alloys 7050 and 8009 were selected because load ratio effects at FCG threshold are not entirely explained by fatigue crack closure. It is believed that closure-free load ratio mechanisms occur in these alloys. Aluminum alloy 2024 was selected for study because it is relatively well behaved, meandering most load ratio effects are explained by fatigue crack closure. A series of constant Kmax threshold tests on aluminum alloys were conducted to eliminate fatigue crack closure at threshold. Even in the absence of fatigue crack closure load ratio (Kmax) effects persist, and are correlated with increased crack-tip damage (i.e. voids) seen on the fatigue crack surfaces. Accelerated FCG was observed during constant Kmax threshold testing of 8009 aluminum. A distinct transition is seen the FCG data and is correlated with a dramatic increase in void production seen along the crack faces. Void production in 8009 aluminum is limited to the specimen interior (plane-strain conditions), promoting crack tunneling. At higher values of Kmax (+_ 22.0 MPaÃ m), where plane-stress conditions dominate, a transition to slant cracking occurs at threshold. The transition to slant cracking produces an apparent increase in FCG rate with decreasing DK. This unstable threshold behavior is related to constraint conditions. Finally, a model is developed to predict the accelerated FCG rates, at higher Kmax levels, in terms of crack-tip damage. The effect of humidity (in laboratory air) on threshold FCG was studied to ensure that environmental effects at threshold were separated from load ratio effects. Although changes in humidity were shown to strongly affect threshold FCG rates, this influence was small for ambient humidity levels (relative humidity between 30% and 70%). Transient FCG behavior, following an abrupt change in humidity level, indicated environmental damage accumulated in the crack-tip monotonic plastic zone. Previous research implies that hydrogen (a component of water vapor) is the likely cause of this environmental damage. Analysis suggests that bulk diffusion is not a likely hydrogen transport mechanism in the crack-tip monotonic plastic zone. Rather, dislocation-assisted diffusion is presented as the likely hydrogen transport mechanism. Finally, the (extrinsic) fatigue crack closure model and the (intrinsic) crack-tip damage model are put in the context of a comprehensive threshold model. The ultimate goal of the comprehensive threshold model is to predict fatigue lives of cyclically loaded engineering components from (small) crack nucleation, through FCG, and including failure. The models developed in this dissertation provide a basis for a more complete evaluation of threshold FCG and fatigue life prediction. The research described in this dissertation was performed at NASA-Langley Research Center in Hampton, Virginia. Funding was provided through the NASA GSRP program (Graduate Student Researcher Program, grant number NGT-1-52174).
An Evaluation of Optical Fiber Strain Sensing for Engineering Applications
Harold, Douglas A. (Virginia Tech, 2012-02-16)
A fatigue test has been performed on 7075-T651 aluminum specimens which were bonded with polyimide coated optical fibers with discrete Bragg gratings. These fibers were bonded with AE-10 strain gage adhesive. The results indicate that lower strain amplitudes do not produce cause for concern, but that larger strain amplitudes (on the order of 3500 Î¼) may cause some sensors to become unreliable. The strain response of acrylate coated optical fiber strain sensors bonded to aluminum specimens with AE-10 and M-Bond 200 strain gage adhesives was investigated with both axial and cantilever beam tests. These results were compared to both the strain response of conventional strain gages and to model predictions. The results indicate that only about 82.6% of the strain in the specimen was transferred through the glue line and fiber coating into the fiber. Thus, multiplying by a strain transfer factor of approximately 1.21 was sufficient to correct the optical fiber strain output. This effect was found to be independent of the adhesive used and independent of the three-dimensional profile of the glue line used to attach the fiber. Finally, this effect did not depend on whether the fiber had a polyimide or an acrylate coating. Further investigation was conducted on the feasibility of using optical fiber strain sensors for monitoring subcritical damage (such as matrix cracks) in fiber reinforced composite materials. These results indicate that an array of optical fibers which monitor the strain profile on both sides of a composite panel may be sufficient for these purposes
Failure processes in unidirectional composite materials
Sundaresan, Mannur J. (Virginia Polytechnic Institute and State University, 1988)
Failure processes in unidirectional composite materials subjected to quasi-static tensile load along the fiber direction are investigated. The emphasis in this investigation is to identify the physical processes taking place during the evolution of failure in these materials. An extensive literature review is conducted and the information relevant to the present topic is summarized. The nature of damage growth in five different commercially available composite systems are studied. In-situ scanning electron microscopy is employed for identifying the failure events taking place at the microscopic level. Acoustic emission monitoring is used for estimating the rate of damage growth on a global scale and determining the size of individual failure events. The results of this study have shown the important roles of the matrix material and the interphase in determining the tensile strength of unidirectional composite materials. Several failure modes occurring at the microscopic scale are revealed for the first time. Further, the results indicate that dynamic fracture participates to a significant extent in determining the failure process in these materials. Based on the results of this study the influence of various parameters in determining the composite strength is described.
Fatigue behavior of ceramic matrix composites at elevated temperatures under cyclic loading
Elahi, Mehran (Virginia Tech, 1996-12-19)
To achieve satisfactory levels of strength, fracture toughness, and reliability for man-rated systems such as jet engines, fiber reinforced ceramic matrix composites are needed. An elevated temperature axial testing system is developed to investigate and characterize fatigue behavior of Nicalon fiber reinforced enhanced silicon carbide matrix. composites at 1800 of under fully reversed cyclic loading. Notch effect on quasi-static tensile response is also considered. Quasi-static and fatigue damage mechanisms and failure modes are examined using various specimen geometries, load levels, fatigue ratios, and laminates stacking sequences by employing a number of NDE techniques. Issues such as damage tolerance and durability are addressed by conducting interrupted fatigue tests at various stages of life for different load levels. Results are compared to the predictions of remaining strength and life, obtained using a performance simulation code. Initial results indicate existence of a threshold stress value which limits the use of the material system.

Browsing by Author "Duke, John C. Jr."

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