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Friction stir welds produced in a rapidly-solidified, powder metallurgy Al-8.5Fe-1.3 V-1.7 Si (wt.%) alloy were characterized in order to investigate the effects of deformation during welding on the weld zone microstructure, hardness, tensile properties, and fracture behavior. A weld produced using a tool rotational speed of 1200 rpm and a traversing rate of 4.3 mm/s exhibited a repetitive pattern of dispersoid-depleted bands that were attributed to the intense deformation that occurred in the vicinity of the tool. The significant softening associated with these regions, and the presence of occasional, irregularly-shaped voids near the boundary between the base metal and the weld zone on the advancing side of the weld, promoted a weld tensile strength of 60–70% of the base metal. The application of a lower tool rotational speed of 428 rpm and a lower traversing rate of 1.9 mm/s promoted fewer bands and a more uniform dispersoid distribution throughout the weld zone, and an absence of defects along the weld zone/base metal interface. Tensile strength of these welds approached 90% of the base metal. Fracture of the transverse-weld oriented tensile specimens for both weld types consistently occurred near the boundary between the weld zone and the base metal on the advancing side of the weld zone, with tensile specimen ductilities appreciably lower than that of the base metal.

Frequency effects on fatigue crack growth rates are examined in aluminum alloy 8009 in sheet and extruded product forms. The investigations show that frequency effects on the fatigue crack growth rates are pronounced in the sheet but minimal in the extrusion. The influence of creep cracking on fatigue crack growth rate is studied through tests with a 60 s hold-time at maximum load at several stress intensity ranges. A 60 s hold-time at maximum load at 315 C tends to retard fatigue crack growth in both the sheet and the extrusion. The mechanism by which this retardation occurs is attributed to stress relaxation at the crack tip. At 204 C a 60 s hold at P[sub max] accelerates crack growth rate in the sheet but not in the extrusion. Vacuum and laboratory air tests show that fatigue crack growth rates in vacuum are lower than in air by about a factor of four. A 60 s hold-time at minimum load has only a minor effect on the fatigue crack growth rates at 315 C and no effect at 204 C, confirming the absence of any strong environmental contribution to crack growth rate. Fracture modes in fatigue, creep crack growth andmore » hold-time at P[sub max] are significantly different. The fractographic results are discussed in relation to the mechanical property data.« less

Plastic deformation introduces changes in a material which include increases in: dislocations, strains, residual stress, and yield stress. However, these changes have a very small impact on the material properties such as elastic modulus, conductivity and ultrasonic wave speed. This is due to the fact that interatomic forces govern these properties, and they are not affected by plastic deformation to any large degree. This is evident from the fact that the changes in electrical resistance and ultrasonic velocity in plastically deformed and virgin samples are very small and can only be determined by highly controlled experiments. Except for X‐ray diffraction, there are no direct nondestructive methods for measuring strain and the residual stress. This paper presents an application of the non‐contact acousto‐thermal signature (NCATS) NDE methodology to detect plastic deformation in flat dog bone Ti‐6Al‐4V samples. Results of the NCATS measurements on samples subjected to incremental amounts of plastic deformation are presented. The maximum temperature attained by the sample due to acoustic excitation is found to be sensitive to the amount of plastic strain. It is observed that the temperature induced by acoustic excitation increases to a peak followed by a decrease to failure. The maximum temperature peak occurs at plastic strains of 12–14%. It is observed that there is a correlation between the peak in maximum temperature rise and the strain at the experimentally determined ultimate tensile strength. A microstructural based explanation for this will be presented. The results are discussed in reference to utilizing this technique for detection and evaluation of plastic deformation.

A newly developed optimization based method is followed to locate the point of impact in anisotropic composite plates for which conventional triangulation technique fails. The new technique works for both anisotropic and isotropic plates. Experiments are carried out by dropping a steel ball on a graphite‐epoxy composite plate and picking up acoustic signals by passive transducers adhesively bonded to the plate at different locations. Predicted points of impact are compared with the true impact point.

As one of the primary data and information sources in the maintenance of USAF Aging Military Fleet, NDE plays a major role in the definition and operation of maintenance processes on these aircraft. To focus new NDE developmental efforts, the AFRL NDE R&D group has the charter to research, develop and transition new capabilities to the field and depot users. This multi‐faceted task is achieved through a balanced NDE and on‐board sensor development program with the ultimate goal to transition technology to the Air Force user Commands. Technology requirements for NDE and Material State Awareness emerge from Air Force Initiatives to realize Condition Based Maintenance and to develop the “Depot of the Future”. This evening session will present an overview of Air Force Initiatives, emerging R&D issues for Structural Health Monitoring and NDE methodologies as well as basic research initiatives within the Air Force Research Laboratory. It is intended that the session provide an open forum to pursue paths for new...

Wave propagation and vibration‐based structural health monitoring methodologies are presented to detect, locate and quantify dent/crack, thermal debond, and corrosion damage in a solid aluminum friction stir weld plate and a sandwich honeycomb thermal protection panel. A wave propagation based method can identify small defects because propagating waves typically consist of small wavelengths while a vibration‐based scheme is better equipped to quantify damage over wide areas of large structures. Near‐real time online diagnostics is achieved by using localized sensing (wave propagation) and distributed sensing (vibration‐based) in an active measurement array. Sensor/actuator arrays have been developed to implement these techniques and portable health management systems have been developed based on the combination of damage detection algorithms, active sensing, and graphical user interfaces. Propagating waves are shown to have a heightened sensitivity to damage located at the anti‐nodes of a friction stir wed plate forced by low frequency environmental vibrations. Measurement of the input forcing in the vibration‐based method is shown to enable damage quantification.

The Thermal Protection System (TPS) used on space shuttles protects the metallic structure from the large amounts of heat created during travel through the atmosphere, both on takeoff and reentry. The shuttle experiences high thermo‐acoustic loading and impact damage from micro‐meteorites, which can cause disbonds, delaminations, chips, cracks, and other defects to the TPS system. To enhance durability and damage tolerance, new TPS tiles with an added protective ceramic‐matrix‐composite layer are being developed. This paper explores the use of pulsed thermography as a quick, diverse, non‐destructive technique, to characterize the TPS system. The pulsed thermography images obtained are presented and analyzed.

A study was conducted to understand acoustic wave propagation characteristics in a ceramic matrix composite (CMC) wrapped tile thermal protection system (CMC+ Foam+ RTV+ SIP+ RTV+ Al) and ceramic foam. Sound velocities were measured in three orthogonal directions on the above material. The attenuation coefficients were also determined for a uncoated ceramic foam. Commercially available standard acoustic emission transducers, piezo‐wafers and polymer based PVDF (polyvinylidiene fluoride) film were employed in the experiments to acquire the acoustic data. The performance characteristics of these sensors will be discussed in light of impact detection. Variation in the wave propagation characteristics along different directions and the role of processing in causing anisotropic acoustic properties in thermal protection systems will be discussed.