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Rocket Thrust Ofhc: Cyclic Fatigueanlysis Chambers: Copper Chamber Low Cycle Fnigw
Rocket Thrust Ofhc: Cyclic Fatigueanlysis Chambers: Copper Chamber Low Cycle Fnigw
R=19740026129 2020-03-23T04:50:03+00:00Z
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NASA CR -
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CYCLIC FATIGUE ANLYSIS OF WH,t*V]
G, C. 3 K w
r Z t f
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w r 5b- ( . (-...lc.
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I
by
R o y W.Miller
Atkins & M e r r i l l Inc.
Ashland, M a s s .
meparad for
PREFACE....~~e.e.~~em.eeee~e~.~~.*..ee~ee.eee*.~.e..*e~..
SUMMARY..........*.........*...*................*.......
1NTR0DUCT10N................,...........................
STRAINANALYSIS............................ ..............
Finite Element Model.. ...............................
Temperature Distribution.. ............................
Results.............................................
Results.............................................
PAGE ~ f l
p B ~ ~ m G iii
PREFACE
A previous report, Referenca 1, prepared under t h i s contract, described
high performance goal which has been established for these engines
demands high chamber pressures with resulting high heat flux levels
flux and high pressure necessitates the u s e of materials with high thermal
and coolant heat transfer. The temperature distribution within the structure
-3-
through which a given chamber is cycled, that determines fatigue life.
complex configurations .
The objective of Volume I is twofold. First, there is the application
strain range data for fatigue life analysis; but a l s o lends insight
strain behavior.
COMBUSTION CHAMBER CONFIGURATION
heat flux and high pressure is the OFHC copper liner. This liner
contains sixty milled axial coolant flow passages. The high thermal
together with the imposed heat flux value, determine the wall thickness.
high thermal conductivity, is that the ribs which divide the cooling
COOLANT INLET
/ COOLANT EXIT I r
STRUCTURAL CLOSE OUT
/ MANIFOLD
(Injector end)
jacket restrains the chamber pressure hoop and thrust loads during
the nickel jacket and copper liner temperatures are measured a t four
nominally a t 0.050 in. (0.127 c m ) from the hot gas side surface,
Operatinu Conditions
The thrust chamber pressure pulse is indicated by the solid line curve
thrust force d u r i n ~the 2.0 second operating phase w a s 4686 lbs. (20840 N).
hydrogen coolant bypass flow is maintained for the 2.1 second period
6 2
Combustion g a s conditions a t the throat station a r e 347 psia (2.39 X 10 N/m )
0 0
static pressure and 6143 R (3413 K) adiabatic wall temperature. Coolant
nickel jacket outer wall temperature. During the engine start transient 8
the copper liner heats a t a greater rate than the low ci:nductivity
nickel jacket. After the copper has reached steady state temperature,
channel bulging and surface roughening of the hot gas side copper
surface occurred. These effects were apparent after only a few cycles
of the engine were altered, and the measured copper temperature levels
showed a gradual increase with each successive firing.
-10-
STRAIN ANALYSIS
It is well known that fatigue life depends on the cyclic strain range
magnitude. One could compute the strain range for each loading
has the same thickness of 0.010 in. (0.025 cm) in the z - direction.
Of course, the throat station w a s chosen for analysis since it is the
in strain and temperature are expected; for example, near the hot g a s
Partition
0
-
.5
El
-6
(o., .121)
L044,. 1211
(x, Y )
Coordinates in
inches
Consistent
with nodes at-
RETSC P
Program 31
Even nodes at
z =0.01 in
(0.025 c m )
-12-
Boundary conditions i n the RETSCP program a r e i n t h e form of prescribed
Coolant
Pressure
Force
value for a l l points on the opposite face. Since the nodal point forces
the sum of the forces in the z - direction equals the thrust force.
If not, the z - displacement is adjusted and the process repeated.
adjusted due t o the thermal expansion force exerted by the copper liner
* .
'i
+ [internal
pressure
][ throat
diameter
]
+ l v e r a g e copper
yield stress
copper radial thickness
a t coolant pas-sage
u =
V!
x
a n 0
[nickel radial thickness
L I
I: Y
T
$
a = t
z
s t + [average copper
yield stress
ILnickel cross
I[
copper cross
sectional area
sectional area]
3
4
1
with the proper axial force solution. In the c a s e of the copper chamber,
'f
the copper strain behavior is s o dominated by the thermal growth, that
the small axial displacement value has little effect. Thus, correction of
i
I.
the initial guess value is not warranted; and, although the stress field in
1 the nickel may be somewhat erronious, the strain range of the copper
1:
Temperature Distribution
is furnished data.
'I'
:%.
3
finite difference computer program. Based on t h e computer output,
with input boundary conditions such that results would agree with
were somewhat lower than the recomputed values which indicated that
in Table I and Figure 5 are in units ( OR) suitable for the RETSCP program.
TABLE I
*
NASA FURNISHED TEMPERATURE DIFFERENCE ( A T = T - T ref)
FOR TWENTIETH TEST CYCLE (T ref = 5 0 0 ' ~ ) .
Element
1 -450.
2 -450.
3 -450.
4 -450.
5 -450.
6 -450.
7 -450.
8 -450.
9 -450.
10 -450.
11 -450.
12 -450.
13 -4 50.
14 -450.
15 -450.
16 -450.
17 -450.
18 -450.
19 -450.
20 -450.
21 -450.
22 -450.
23 -450.
24 -4 SO.
25 -450.
26 -450.
27 -450.
28 -450.
29 -450.
30 -4 50.
31 -450.
32 -450.
33 -450.
34 -450.
0
*Note: Values are in OR ( 1 . 8 x K) which is suitable unit for RETSCP.
r
J44
(b) s t a r t 0
steady
state 413
chamber
overs hoot firing
56 8
830 776 893 841
9 9 *
9 * * a
951 896 864
-450 -45C
9
I
-262 %-450
cooldown 0
(a) precool-
transient -27$ intercool -450
peak
overshoot -288 -4 5C
-450 -450 -
?..
-303 -3oc
rn
-e e *
-450 -450 -450
*~
I t turns out t h a t for plastic behavior, the true stress-true strain curve
(about 30%). Since strain hardening of copper occurs in the first few
curves.
The plastic portion of the curves were constructclrd directly from Figure 6.
same shape. Results are shown by the dash line curves i n Figure 8.
The bi-linear representations, which were used for the rocket chamber
Note, that for small elasto-plastic strain values (less than 0.5%), the
very well. Thus, a set of bi-linear curves for strains up to 0.5% were
-23-
0
Yield s t r e s s a t -320'~ (-195 C ), Reference 11
Yield stress a t room tempe~ature,Reference 10
Stress -psi Yield stress a t 1000°F (538%), Reference 10
N / ~ ~ )
Stress a t Nf/2 for straln shown, at
1 0 0 0 (538%),
~~ Reference 10
-320'~
5000
/ --' ---.-
A
-- cyclic
/@
/ - -
1 0 0 0 (~ ~ 3 8 ~ ~ )
(344 7)
0 I Percent
1 2 strain
30,oon--
(20684)
25,000--
(17237)
Stress - psi
(10-4 ~ / m
2, I
0
.
a
1
Percent
Strain
0 1
I
2 J
Figure 8 . Bi-linesr cyclic stress-strain curves for OFHC copper
up t o 3 percent strain .
-2 5-
-
Stress p s i
(1o ' ~x ~ / 2,m
Percent Strain
were used in the analysis for element number 7,8,9 and 10. The
applicability of this strain level for thos.? element? will be apparent later.
A summary of a l l data used in the RETSCP program for the CFHC copper combustion
Structural Analysis
0 0
The chamber is initially subjected t o a 50 R (28 K) precool temperature in
combination with the coolant pressure load. Since the copper has s larger
are induced in the nickel jacket. The high strength nickel jacket is
Upon heating t o the start transient peak overshoot level, the sitrlation
English Metric
Units Units
( RETSC P)
Thermal Expansion Coefficient:
Nickel
Copper
Modulus of Elasticity:
Nickel 3 0 . 0 ~ 1 0+6 p s i
Copper-cold 1 6 . 6 ~ 1 0 ' ~p s i
Copper-hot 10.0x10+~ p s i
Poisson's Ratio:
Nickel
Copper
relaxed; so is the thermal strain level relaxed. The important p0ir.t 's that
this relaxation takes place along the elastic line. This point will be
illustrated later. The strain relaxation may terminate either with t . nsile
The second test cycle will produce similar qualitative behavior with two
the cycle, will differ from the first loading cyc!e. Second, the material
cycles will "shake-down" the effect of the residual strain starting point.
Also, strain hardening of the copper will diminish after a few cycles,
Reference 12 and 13. For the present calculation, work hardening is not
maximum strain range for any cycle will be determined by the peak t o peak
-29-
RETSCP Prosram Execution
The detailed copper chamber strain c y c l e w a s computed using t h e 34
together with cold material properties data and zero chamber pressure.
punch card residual strain data for e a c h element. The punch cards a r e
Results
element a t the hot gas side surface beneatn the rib, with temperature
yielding to the point (a). During the start transient, yielding occurs
achieved, the stress relaxes along the elastic line from (c) toward (d),
betw~rtnpoints (f) and (g) , which will later be used t o predict fatigue life.
Stress-strain cycles are shown in Figure 11, 12, and 13 for elements
elements 15, 17, 30, and 34 is plotted versus the calculation loop
each element.
from the hot and cold transient overshoots is given since these are
(inches) and the yield data summary (inches/inch or psi where applicable)
+ - - -- T
I E ma%* Calculation
0 . "- - $x4,3<-- I
loop
Number
3 '4 5 ' 6 7 1 8 w
$Gain
Range
E min.
total and plastic strains for the cooling cycle is the elastic strain,
corresponding to the line 3-4 at the top of Figure 14. Thus, the
effective strain range for the element, is the total strain from the heating
Note, that the peak strain range location does not coincide with the
coolant side and relieve compression on the chamber side, along the
line (i) - (ii) i n Figure 15. Thus, the incompressibility of plastlc strains
increases the strain magnitudes toward the liner rib along the hot wall,
By extrapolation (cross plots of the strains at the element centers) to the hot wall
surface, the maximum strain range is 2.46%, at point (iii) in Figure 15,
0
where the maximum copper temperature is 970 F ( 521°c). Strain range
values are generally between 2.0 and 2.5 percent throughout the hot
-39-
The strain range r e s u l t s , which a r e t h e b a s i s of the life estimate,
the s t ~ transient,
t could lead t o t e n s i l e hold strain under hot conditions.
fatigue test data. A fatigue damage law is used to relate the actual
Material R o ~ e r t i e s
..
p r e d i c a ~ i o n(c f Reference 15); namely,
The comparison not only shows the applicability of the Universal Slopes
C y c l e s to Failure, Nf
and 1 0 0 0 ~
(538'~)
~ Reference 17. For t h e s e conditions, fatigue
based 3n t h e 1 0 0 0 (538'~)
~ ~ d a t a shown in Figure 17 (dash line curve).
Fatiuue Damase
linearly a s follows:
test data. Had t h e strain calculation been performed for various loading
-44-
noted t h a t , for t h e copper test chamber, experimental run times were
Results
Recall that the maximum value of effective strain range for the
copper chamber life (39 c y c l e s ) , and the maximum strain value for
example, cycles five and forty. Account for cycle by cycle strain
dimensional phenomena.
not only produce more accurate life estimates; but a l s q lead to greater
Modulus of elasticity
Pressure
Chamber pressure
Reduction i n area
Temperature
Cartesian coordinates
Strain (effective)
Stress (effective)
Yield stress
Poisson's ratio
portion of the test c y c l e . The data are input from the sixth
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- 0
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1
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f 8
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'G-
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00
OG-
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'0 - 0
0 1
1
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'0- '0- 0 1 0 8 9
-0- '6 'i i I O L 9
CGGCGCCG*€- -0- '0
C'
- i t
t . 1 0 4 9
0 9 9
00000000'E- *G
'0-
'C-
'0-
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*o-
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1
1
1
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2
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f 9
9
9
'0-
'G- 'G 'il G I 1 1 9
'C- 'G- 'G- G T O 9
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'G- '0- '0- 0 1 1 8 %
'G- 'L '0 C 1 1 L S
'0- '0- '0 - C 1 J 9 S
'6- '0 -0 0 1 O S S
LCGCGCCC'€- OC- *C - C G
331Ud B Z S * I G A
C S
APPENDIX C --- SAMPLE RETSCP OUTPUT DATA
The following data from the hot and cold transient overshoots i s
of the c y c l e .
mmI-
0
I-NO
0-0
. . ..
mm
m N
9C
sr-m m 9
*N N NI-
mP
N 0N
NNU mm
NNd
w*
m 9
ou'
.
N*
NN
00
on
Y q t l 4 5 2 t PRICE
2. Langer,B.F,,FatigueFailurefromStressCyclesofVarying
5. Smith, R . W . , H i r s c h b e r g , M . H . , a n d M a n s o n , S . S . ,
M a c M i l l a n C o m p a n y , 1968.
D a t a from a b o v e a v a i l a b l e t h r o u j h C o p p e r Data C e n t e r ,
1956.
.
Coffin, C F. , a n d Tavernelli, J F. . , The C y c l i c Straininq
a n d Fatique of M e t a l s , T r a n s a c t i o n s of t h e M e t a l l u r g i c a l
Vol. 8 6 , 1953.
TM-X-52270, 1967.
-64-
REFERENCES, Cont'd.