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Book: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003445
EISBN: 978-1-62708-195-5
... Abstract This article describes the role of the full-scale testing in assessing composite structural systems of aircraft and qualifying them for in-service use. The typical full-scale tests include static, durability, and damage tolerance. The article discusses the parameters to be considered...
Abstract
This article describes the role of the full-scale testing in assessing composite structural systems of aircraft and qualifying them for in-service use. The typical full-scale tests include static, durability, and damage tolerance. The article discusses the parameters to be considered when developing the basic requirements for the static test. These parameters consist of material considerations, moisture and temperature effects, structure size, load application alternatives, instrumentation requirements, test procedure considerations, ultimate load requirements, and test results correlation. The basic requirements common for durability and damage tolerance tests, including environmental effects and inspection requirements, are also discussed.
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Published: 01 January 2001
Book Chapter
Testing of Pressure Vessels, Piping, and Tubing
Available to PurchaseSeries: ASM Handbook
Volume: 8
Publisher: ASM International
Published: 01 January 2000
DOI: 10.31399/asm.hb.v08.a0003328
EISBN: 978-1-62708-176-4
... under cyclic loading. Full-scale testing facilities and the typical test results required for various applications are discussed. The article also presents information on the transferability of mechanical properties of materials. pressure vessels piping tubing fracture mechanics longitudinal...
Abstract
This article provides an overview of the safety aspects and integrity concept for pressure vessels, piping, and tubing. It focuses on the fracture mechanics approaches used to validate components with longitudinal cracks and circumferential cracks and to analyze crack growth behavior under cyclic loading. Full-scale testing facilities and the typical test results required for various applications are discussed. The article also presents information on the transferability of mechanical properties of materials.
Image
Full-scale fatigue test (FSFT) stub flange critical fatigue crack location ...
Available to PurchasePublished: 01 June 2024
Fig. 16 Full-scale fatigue test (FSFT) stub flange critical fatigue crack location and detection (red arrow in inset) using dye penetrant under ultraviolet light. The common noncritical “nuisance” cracking location for some service aircraft and also observed during the FSFT test is shown
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Optical fractograph of the excised full-scale fatigue test stub flange fati...
Available to PurchasePublished: 01 June 2024
Fig. 17 Optical fractograph of the excised full-scale fatigue test stub flange fatigue crack, showing the estimated full extent of the crack (curved red line) and the quantitative fractography (QF) measurement trajectory (dashed red line)
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Published: 01 January 2001
Book Chapter
Fatigue Crack Growth Markers to Aid Quantitative Fractography
Available to PurchaseBook: Fractography
Series: ASM Handbook
Volume: 12
Publisher: ASM International
Published: 01 June 2024
DOI: 10.31399/asm.hb.v12.a0006877
EISBN: 978-1-62708-387-4
... regimes for coupons, components, and, particularly, full-scale fatigue tests. crack-growth regimes fatigue crack growth markers fatigue test quantitative fractography DURING DESIGN and when considering the in-service structural integrity of mechanical systems, some testing is usually done...
Abstract
This article discusses several examples of fatigue load histories that intentionally create artificial fracture-surface markings during testing such that they are measurable by post-test quantitative fractography (QF). It reviews a number of methods for providing fatigue fracture-surface markers to aid QF of fatigue crack growth (FCG). These methods are based on load changes, including reordering the basic load histories and/or adding loads to them. The article also provides some guidelines for obtaining recognizable FCG markers for a variety of load histories and crack-growth regimes for coupons, components, and, particularly, full-scale fatigue tests.
Series: ASM Handbook
Volume: 13C
Publisher: ASM International
Published: 01 January 2006
DOI: 10.31399/asm.hb.v13c.a0004131
EISBN: 978-1-62708-184-9
... such as structural parts, engines, and subsystems. It describes the aging management processes such as full-scale structural testing and practical life-enhancement methods. The article reviews control and prevention systems such as usage and health monitoring systems necessary to provide effective corrosion...
Abstract
Aging is a process where the structural and/or functional integrity of components will be continuously degraded by exposure to the environmental conditions under which they are operated. This article discusses aging mechanisms in various components of military systems such as structural parts, engines, and subsystems. It describes the aging management processes such as full-scale structural testing and practical life-enhancement methods. The article reviews control and prevention systems such as usage and health monitoring systems necessary to provide effective corrosion maintenance on military systems. Failure prediction techniques, namely, the equivalent pre-crack size approach, life-cycle cost modeling and simulation, and holistic life-prediction methodology are also discussed.
Book Chapter
Damage Tolerance Certification of Commercial Aircraft
Available to PurchaseBook: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002393
EISBN: 978-1-62708-193-1
..., the Civil Aviation Authority (CAA) in the United Kingdom became concerned about the loss of fail safety with time due to widespread fatigue damage. The CAA considered it risky that on U.S. designs, the fatigue testing of large components and full-scale structures was not continued for as long...
Abstract
Damage tolerance is a philosophy used for maintaining the structural safety of commercial transport aircrafts. This article describes the structural evaluations necessary to comply with the regulations contained in the Federal Air worthiness Requirements 25.571 whose guidance is given in Advisory Circular 25.571-1A from the Federal Aviation Administration. It provides an overview of the historical evolution of damage tolerance philosophy and presents a discussion of the design philosophies and a summary of the evaluation tasks for damage tolerance certification.
Book: Composites
Series: ASM Handbook Archive
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003439
EISBN: 978-1-62708-195-5
... a single confirming test of a full-scale component or a full-scale structural assembly. Fig. 1 The building-block pyramid for testing of composites Upper-level (especially full-scale) tests are not always performed at the worst-case design environment. Data from the lower levels...
Abstract
Composites are complex engineered materials that often behave differently than common isotropic materials. Before testing a composite material, or before ordering or supervising such testing, the responsible party should review certain considerations. This article provides an overview of such considerations, namely, the differences between the testing of composites and testing of isotropic materials, role of certification agencies and importance of their involvement, building-block approach to composites testing, determining the purpose of testing, normalizing results, and statistical data reduction.
Book Chapter
The U.S. Air Force Approach to Aircraft Damage Tolerant Design
Available to PurchaseBook: Fatigue and Fracture
Series: ASM Handbook
Volume: 19
Publisher: ASM International
Published: 01 January 1996
DOI: 10.31399/asm.hb.v19.a0002394
EISBN: 978-1-62708-193-1
... a reliability-based method to establish the operational life. This was commonly called the “safe-life approach.” The safe-life approach relied on the results of the laboratory fatigue test of a full-scale aircraft. The time-load history of the test aircraft was carefully selected to emulate the actual loadings...
Abstract
The inclusion of damage tolerance design and a systematic review of design procedures allow the U.S. Air Force to design, manufacture, and maintain systems that are structurally safe and economically prudent. After a brief introduction of fracture mechanics, this article describes the particular aspects that relate to damage tolerance in aircraft design. It discusses the use of fracture mechanics as a method of predicting failure, understanding failure mechanisms, and suggesting inspection methods to protect against failure in pressure vessels. Various programs of U.S. Air Force to design aircraft structure, namely, airframe structural integrity programs, engine structural integrity program, and mechanical subsystems structural integrity program are also discussed.
Image
A set of stack-focused optical images for the full depth of a fatigue crack...
Available to PurchasePublished: 01 June 2024
Fig. 23 A set of stack-focused optical images for the full depth of a fatigue crack in an aluminum alloy 7050-T7451 component. Nine stack-focused images were aligned manually to give this image. The component was from a full-scale fatigue test, and the purpose of the montage was to allow
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Results of experimental moment versus crack length for tests for circumfere...
Available to PurchasePublished: 01 January 2000
Fig. 22 Results of experimental moment versus crack length for tests for circumferentially cracked pipes (333 full-scale pipe tests)
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Schematic of Rolltact test, in which component wear indicates expected wear...
Available to Purchase
in Wrought and P/M Superalloys
> Properties and Selection: Irons, Steels, and High-Performance Alloys
Published: 01 January 1990
Fig. 26 Schematic of Rolltact test, in which component wear indicates expected wear of a rolling contact bearing operated under similar conditions. The drive ball and cup, alternate balls, and test separator are representative of a full-scale bearing. Test conditions are: spindle speed, 2000
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Book Chapter
Mechanical Testing of Gears
Available to PurchaseSeries: ASM Handbook
Volume: 8
Publisher: ASM International
Published: 01 January 2000
DOI: 10.31399/asm.hb.v08.a0003327
EISBN: 978-1-62708-176-4
.... After bench testing, it is not unusual to subject the transmission to full-scale testing , where the transmission is subjected to controlled but actual operating conditions to determine the performance of the specific gear. Both bench and full-scale testing represent very specific application-oriented...
Abstract
Mechanical tests are performed to evaluate the durability of gears under load. Gear tooth failures occur in two distinct regions, namely, the tooth flank and the root fillet. This article describes the common failure modes such as scoring, wear, and pitting, on tooth flanks. Failures in root fillets are primarily due to bending fatigue but can be precipitated by sudden overloading (impact). The article presents contact stress computations for gear tooth flank and bending stress computations for root fillets. Specimen characterization is a critical part of any fatigue test program because it enables meaningful interpretation of the results. The article describes four areas of the characterizations: dimensional, surface finish/texture, metallurgical, and residual stress. The rolling contact fatigue test, single-tooth fatigue test, single-tooth single-overload test, and single-tooth impact test are some of the gear action simulating tests discussed in the article.
Image
A panorama-stitching algorithm was used to automatically stich (with some m...
Available to PurchasePublished: 01 June 2024
Fig. 24 A panorama-stitching algorithm was used to automatically stich (with some manual help) ten images taken with a stereomicroscope of a fatigue fracture surface in aluminum alloy 7050-T7452. This was accomplished using Adobe Photoshop. The component was from a full-scale fatigue test
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Book Chapter
Closed-Die Steel Forgings
Available to PurchaseSeries: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003097
EISBN: 978-1-62708-199-3
... with, and interpretation of, the behavior of material in actual use. The dynamic behavior of a full-size structural component seldom can be accurately predicted from simple room-temperature tests on small specimens. Analytical studies coupled with model or full-scale testing can augment simple tests in interpreting...
Abstract
Forging is the process of working hot metal between dies, usually under successive blows and sometimes by continuous squeezing. This article describes the material selection criteria, quality assurance tests for forged components, and the dimensional tolerances of closed-die steel forgings. It provides an overview of the mechanical properties of wrought materials. The article also includes information on the fundamentals of hammer and press forgings and the design of hot upset forgings.
Image
Deep-focus optical fractograph details of the excised full-scale fatigue te...
Available to PurchasePublished: 01 June 2024
Fig. 18 Deep-focus optical fractograph details of the excised full-scale fatigue test stub flange fatigue crack. (a) Main origin, also showing the ion vapor deposition (IVD) aluminum coating layer. (b) Example of a complete block of simulated flights, equivalent to approximately 320 simulated
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Quantitative-fractography-measured crack depth versus full-scale fatigue te...
Available to PurchasePublished: 01 June 2024
Fig. 19 Quantitative-fractography-measured crack depth versus full-scale fatigue test (FSFT) fatigue crack growth (FCG) life for the excised stub flange fatigue crack, combined with the lead crack fatigue lifing framework (LCFLF) estimate of the stub FCG life to failure if the crack had
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Series: ASM Handbook
Volume: 13A
Publisher: ASM International
Published: 01 January 2003
DOI: 10.31399/asm.hb.v13a.a0003663
EISBN: 978-1-62708-182-5
... and mass loss of certain model components. Although less expensive than full-scale component testing, physical scale modeling has many of the disadvantages of component testing. In addition, a great inaccuracy in conductivity scaling stems from the fact that the polarization resistance of the materials...
Abstract
Galvanic corrosion, although listed as one of the forms of corrosion, is considered as a type of corrosion mechanism that is evaluated by modifying the tests used for conventional forms of corrosion. This article focuses on component testing, computer and physical scale modeling, and laboratory testing methods of evaluating galvanic corrosion. The laboratory tests fall into two categories, namely, electrochemical tests and specimen exposures.
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