Report 1762 — HYDROMECHANICS a EXPLORATORY INVESTIGATION OF NONWELDED Ze PRESSURE HULLS FOR HYDROSPACE VEHICLES O by AERODYNAMICS a O i Arthur C. Macurdy STRUCTURAL MECHANICS i APPLIED MATHEMATICS O fs STRUCTURAL MECHANICS LABORATORY * RESEARCH AND DEVELOPMENT REPORT TICS AND ATION March 1964 Report 1762 1110-170 648 (Rev 1—64) EXPLORATORY INVESTIGATION OF NONWELDED PRESSURE HULLS FOR HYDROSPACE VEHICLES by Arthur C. Macurdy March 1964 Report 1762 S-RO11 O1 O1 TABLE OF CONTENTS ABSTRACT eoeeeeeeeeceeeeeee2eee2e2ee2 ee e2e2e2e2e2e2282 282822 e2FFFe282282F22908 028 S880 1 INTRODUCTION eeoeeeecenvneeee ee eeeeeeeeeeeereeeeeeeeeeeeeeeeeee8 882028 & DESCRIPTION OF MODELS e@eoeeeeeseeeee eee eee eeeeeeeeeeeeeeeee7e22828880 0 TEST PROCEDURES AND RESULTS e@oeoeeeeeeeeseeeeeeeeeeeeee eee ee ee ee eee SUMMARY @eeeeeeeee2eoeceeeeeeeeeneeeeeeeeeeneeeeeeeee220808227878 88888880 RECOMMENDATIONS eaooeeeeeeeeoeeeeeeeeeeeeeeeeeeeeeeee eee eee ee eeeee ee ACKNOWLEDGMENTS e@ceeceeeeeeneece2eeeeeeeeee2seeeee7eeee2e2e2e2e8 282828 F288 8888 O REFERENCES e@eceeeeneeeeeeeeoeneeeeeeeeeeeee2e7ee eee eeeeeeeeeeeeeeee2 eee 0e 10 1 2 3 DESCUSSION cc ccc ccc ccc ccc cece cece cece cece cece ee sececsecccescecece 4 9 9 9 LIST OF FIGURES Page Figure Models Before TeSt ccccccccccccvccccccccccescccccccccces 12 Figure Sketches of Models e@eeoeoevceeeaneeoeeeeeaeeoevseenoeeeeoeeeeoeeoe eee 8 8@ 14 Figure Measured Strain SenSitivitleS .cccccccccccccccccccccvcs 15 Figure 4 — Models After TeSt cccccccccccccccccccccccccccccccccccce 18 a & Ww nw FH 1 Figure Mechanical Joining TechniqueS) ...ccccccccccccccccccccce 19 LIST OF TABLES Page Table 1 - Comparison of Experimental and Theoretical Strain Sensitivities at Midbay ccccococecccccccccccccesceccccccs 20 Table 2 - Ratios of Theoretical Collapse Pressures to Experimental Collapse Pressures eeeoeoevoovoeve2en0e0e2e2e020e2 0202020202080 8082 8080808008878 8 88 SG 20 Table 3 -— Experimental and Prototype Collapse PressureS ....cceccee 21 Li ABSTRACT The feasibility of fabricating a deep-submergence pressure hull composed of rings joined by means other than welding was explored in tests of three structural models (two of aluminum and one of titanium) designed for a collapse strength of 10,000 psi. These tests demonstrated that hulls can be built without welding and that these hulls can have collapse strengths comparable to monolithic hulls. Longitudinal strength, watertight integrity, and corrosion protection, which were not explored by these tests, can be provided by any of several mechanical techniques without compromising collapse strength. INTRODUCTION Growing interest in the ocean depths both in scientific and military circles has emphasized the need for vehicles capable of operating at great depths. It is recognized that the materials and the fabrication techniques now in use place a severe limitation on the size and maximum operating depth of positively buoyant vehicles. Much interest has been show in using light, high-strength materials such as aluminum, titanium, glass- reinforced plastics, and high-strength steels. Solid glass is also being investigated. The most difficult problem in utilizing these new materials is that very few of them can be welded and still retain their strength character- istics. In addition, the thick sections required for larger diameter hulls make welding extremely difficult and expenSive even where it is possible. Techniques have been proposed for eliminating or reducing the welding problem where large rings are used to form the strength elements of the cylindrical pressure hull. Reynolds proposed a hull of aluminum rings held together with tension rods and covered with a thin coating of pure aluminum for corrosion ik detent The latest design of the ALUMINAUT pressure hull cylinder is composed of rings held together by Benes The David Taylor Model Basin is currently investigating composite-type con- struction in which the strength rings are secured and protected by a thin 3 outer jacket of weldable or otherwise easily fabricated material. ” Dyetenenees are listed on page 10. For this study three structural models, two of aluminum and one of titanium were assembled from machined rings and were tested to determine whether hulls built from separate rings could have collapse strengths comparable to monolithic hulls. This type of hull, consisting of separate rings, would be adaptable to a variety of techniques for attaining longi- tudinal strength and watertight integrity. This report summarizes the results of the tests of these three models. DESCRIPTION OF MODELS The three models were deSignated PJ-1S, PJ-1L, and PJ-2. Models PJ-1S and PJ-1L were made from 7079-T6 aluminum alloy and Model PJ-2 from 6Al=4Va titanium alloy. Yield Strengths of 62,000 and 150,000 psi were used in the design calculations for aluminum and titanium, nesnectivels. Based on these strengths, the models were designed for a collapse strength of 10,000 psi, A value of 10.5 x 10° psi was assumed for the Young's modulus of the aluminum, and a value of 16.0 x 10° psi for the titanium. A Poisson's ratio of 0.3 was assumed for all material. The models are shown in Figure 1, and relevant dimensions are given in Figure 2. The aluminum models (PJ-1S and PJ-1L) had rectangular inside frames and heavy shell segments of uniform thickness. The typical bay weighed 67.9 percent of its displacement weight in sea water. The area per unit length of the hull section was obtained by allowing the average two- dimensional Hencky-Von Mises stress to reach about 62,000 psi at a pressure of 10,000 psi. A highly stable shell structure is required to permit utilization of the full-yield strength of the material. To this end, the frames were deSigned for a general-instability es snel of about 30,000 psi. A short frame spacing was selected to minimize bending in the shell due to hydrostatic loads and to provide a high elastic-shell buckling strength. Model PJ-1S was 1.7 diameters long, representing a finite com- partment length, and was closed at the ends with flat aluminum plates; Model PJ-I1L was four diameters long, approximating a semi-infinite cylinder, and had hemispherical end closures. Models PJ-1S and PJ-l1L were designed to evaluate the effect of bulkhead spacing. Both models had identical typical bays and had grooves at each frame. These grooves were filled with an aluminum-impregnated epoxy, which sealed the joint and provided limited longitudinal strength. The titanium model (Model PJ-2) had a double shell separated by thin webs. The typical bay weighed 53.8 percent of its displacement weight in Sea water. In this model, area per unit length of the hull section was obtained by allowing the average circumferential stress over the section to reach 150,000 psi at a pressure of 10,000 psi. The depth of the web and the average thickness of the shells were chosen to obtain an elastic general-instability pressure for a Semi-infinite cylinder of about 25,000 psi. The shell segments were designed to eliminate bending due to the hydrostatic load.” This was done by varying the thickness of the shell in the longitudinal direction. Also, as in the first two models, the end bays of Model PJ-2 were shorter than the typical bay. Model PJ-2 was 1.6 diameters long and was closed at the ends with flat steel plates. Grooves on the inside and outside at each web were filled with an artificial rubber compound. The artificial rubber was chosen for ease of application in the laboratory, rather than as a suggested prototype material. It was also used to seal the closure plates to the model. TEST PROCEDURES AND RESULTS The models were instrumented with foil-type resistance strain gages. The arrangement of the gages is shown in Figure 3. Model PJ-1S was tested to collapse in the 17-inch diameter, high-pressure test tank at the Model Basin. Model PJ-1L was tested almost to collapse in the l7- inch pressure tank and collapsed in the 9-inch-diameter, high-pressure test tank. Model PJ-2 was tested to 7000 psi in the 13-inch diameter, high- pressure test tank and collapsed in the 9-inch pressure tank. Strain data were obtained only during tests in the 17 and 13-inch tanks. At least three runs were made for each model to obtain strain data. The loads were applied to Model PJ-2 at the same rate as the compression specimens. Model PJ-1S collapsed at 12,500 psi, Model PJ-1L at 11,900 psi, and Model PJ-2 at 10,100 psi. Strain sensitivities devised from the initial slopes of the pressure-strain plots are given in Figure 3. Figure 4 shows Models PJ-1L and PJ-2 after test. DISCUSSION The measured Strains, presented in Figure 3, are compared with theoretical strains in Table 1. The agreement with theory is very good, indicating that the elastic strains were not affected by the structural discontinuities at the frames. The calculations are from the theory of Salerno and Puillasy aS presented by Lunchick and Shome,” All of the models failed by inelastic general instability in the n=2 mode. This is indicated by the appearance of the models after test (Figure 4) as well as by the theoretical calculations. The computed collapse pressures for Models PJ-l1S and PJ-1L indicate a very high degree of stability in the elastic shell buckling modes and a margin of at least 20 percent in the inelastic shell buckling modes; see Table 2. Because of the highly stable shell design, the theoretical in- elastic shell buckling presemmes 290° correspond to strain levels in excess of those measured in tests of material compresSion specimens. The ratios reported in Table 2 correspond to average strain levels of 1.5 percent. No theory is available to compute the shell-buckle pressures for nonuniform Shells such as those of Model PJ-2. All of the theories presented in Table 2 assume the models to be of monolithic construction. The experimental collapse pressures and the scaled collapse strengths are given in Table 3. To compare the ring models with monolithic hulls, data from two other models are also included in Table 3. Model DSRV-P, ° a Small machined-aluminum model, similar to Model PJ-1S was 1.4 diameters long and had a modified-Bryant critical buckling pressure of 3.55 times its collapse pressure. Since it is impossible to machine a monolithic sandwich hull such as Model PJ-2, a similar two-piece hull is included in this discussion for comparison. Model OV-4 was made by inserting a cylinder with outside rectangular frames into a closely fitted jacket, which formed the outer shell. Model ov-4t had nearly the same Semi-infinite, elastic, general-instability collapse pressure as Model PJ-2 and was 4 diameters long. Generally, the collapse strength of models that fail inelastically is proportional to the yield strength of the material and to the weight- to-displacement ratios. This permits comparison of collapse strengths among Similar models. The scaled collapse pressures for Models PJ-1S and PJ-1L were obtained by scaling the model yield strengths to 62,000 psi. The scaled collapse pressure for Model PJ-2 represents a semi-infinite hull of the same typical bay geometry and with a yield strength of 150,000 psi. The collapse strength of Model DSRV-P was scaled to 62,000 psi yield strength and a weight-to-displacement ratio of 67.9 percent. The collapse strength of Model OV-4 was scaled to a yield strength of 150,000 psi and a weight-to=displacement ratio of 53.8 percent. The comparisons shown in Table 3 illustrate that ring construction need not result in any sacrifice in collapse strength compared to monolithic hulls. Since the distortion and weakening effect of welding Stresses are not present, ring construction may permit some increase in collapse strength relative to welded hulls. A submarine pressure hull is designed principally to resist external hydrostatic pressure. However, in addition to the hydrostatic loads, a submarine or other structure is subjected to overall bending moments. To resist these bending moments, the structure must possess longitudinal tensile strength in addition to its hydrostatic collapse strength. This tensile strength is required only when operating on or near the surface. At deeper depths, the longitudinal, hydrostatic compressive load exceeds the tensile load of the bending moments and less longitudinal tensile strength is required. For example, an oceanographic research statign and bottom=based vehicles could be assembled on site With a minimum of tensile bending. For vehicles which must operate on the surface or at high speed, some form of mechanical joining is required. The fundamental considerations in designing a joining device are weight, volume, and stress concentration in the pressure hull. For a given level of longitudinal strength, it is desirable that the least excess weight be added to the structure by the joints. In addition, it is desirable to consume as little as possible of the valuable interior space. Any joining procedure which induces stress concentration in the pressure hull may lower the collapse strength or induce a fatigue problem. Many mechanical joining techniques have been proposed for this application. A few are considered here. The following discussion presents several typical ideas and some of their strengths and weaknesses. The rings could be held in place by tension wires or rods Secured at the bulkheads (Figure 5a). This method has the advantage of low weight since very high-tensile-strength steel may be used. One problem involves the location of the rods. They cannot pierce the frames or webs Since, this would introduce severe stress concentrations particularly for nonductile materials. If they are inboard of the frames, they are less efficient structurally and consume valuable interior space. Ideally, they would be placed outside the hull, but there they are subject to mechanical damage and to corrosion. Bolts might be used to secure the rings (Figure 5b). This technique is being considered for ALUMINAUT. An important problem here is the stress concentration in the bolt holes. Large, round taper pins might overcome the stresS-concentration problem of the holes (Figure 5c), but they would be loaded in shear and would have a Stress-concentration problem under longitudinal loading. Clamps and similar devices carry no hydrostatic load and may be prohibitively heavy for joining individual shell and frame rings. However, sections consisting of several frame and shell Sections could be joined by a system as Shown in Figure 5d. The sections could be assembled by one of the other techniques considered here or, for small diameter hulls, could be machined. This procedure is being considered for deep-running torpedoes. The clamping ring may be formed in several segments which are joined by bolts. In the technique of composite construction, the rings are inserted into a jacket of weldable or otherwise easily fabricated material (Figure 5e). The jacket yields during the initial submergence, holds the rings in place, and provides watertight integrity and corrosion protection. The main difficulty with this technique is in the repair of the jacket. Some materials, particularly aluminum and glass-reinforced plastics, are heat sensitive, and heat applied in welding the jacket might seriously weaken the inner rings. This problem could be overcome by using an epoxy or glass-reinforced plastic jacket or, possibly, an intermediate heat shield. The rings could also be designed to be self-locking. This could be done by allowing for positive interference and shrink-fitting the rings together (Figure 5f). Aside from the difficulties in fabrication, this technique precludes later separation of the rings and may be a source of stress concentration if close tolerances are not maintained. The rings could also be made with threads and screwed together (Figure 5g); here the main problem is the stress concentration at the root of the threads. One of the most interesting joining and sealing techniques available is the use of adhesives. Adhesives have the significant advantages of low weight and economy of application. They can be used either alone or in combination with other mechanical bonds. The availability of epoxies or similar materials with the necessary bonding properties and tensile strengths has not been established. It is felt that the rapidly expanding adhesive technology will be able to provide a suitable material if the need is eStablished. In addition, adhesives have two critical defects which impair their usefulness in deep-submergence applications; one is a problem in joint deSign and the other a problem in materials. An epoxy adheSive was uSed on the deep-submergence Krupp sphere of the bathyscaphe TRIESTE to hold the three segments of the sphere together. The joint was a Simple glue-line with a layer of epoxy between the two metal surfaces. When the Krupp sphere surfaced after the first deep dive (Dive 61), the two joints were parted. Fortunately, there was no immediate danger to the occupants of the bathyscaphe since the Segments were held together by the pressure of the water; for further dives, the sphere was held together by a system of rings and anise — The failure of the TRIESTE bond was probably caused by the dete- rioration of the epoxy under high compressive loads. Epoxy reSins and other adhesives have relatively low Young's moduli and compressive yield strengths. This means, of course, that they may experience excessive deformation when subjected to the same stress aS a metal. Conversely, if the adhesive is subjected to the same deformation as a metal, it will carry a very much smaller stress. The models in this report illustrate one type of joint where the adhesive may act as a bond and seal, without being subjected to high compressive stresses. Much work is required to evaluate this, and other, improved designs for adhesive joints. It is important that the presence of the groove for the adhesive joint did not seem to impair the collapse strength of the models. In addition to deterioration due to loading, adhesive materials are Subject to eventual deterioration due to exposure to salt water and to biological fouling. These material problems must be solved by developing new adhesives and material-protection techniques. Until they are solved, adhesives will be limited to short-term applications or will require periodic replacement. The primary advantage of ring conStruction is that it permits the use of many light, high-strength nonweldable materials for deep-submergence pressure hulls; but there are a number of other features which may produce considerable savings. The combining of rings into a pressure hull by mechanical means is essentially a faster and less expensive operation than welding and requires less time spent in the shipway. This potential Saving is balanced by the greater machining costs associated with ring construction. In addition, it is often necessary to open a hull to make repairs or to replace machinery. It is not possible to open a hull by cutting or burning a ring Since it cannot ordinarily be rewelded; but it may be practical to Separate two rings at a joint, and then reassemble the section after the repair work is completed. Present forging capacity limits the maximum size of nonweldable metals to a diameter of about 12 to 15 feet. Aluminum must be forged to obtain its highest yield strength, but titanium and steel may be welded and then heat treated to higher strengths. It is felt that the primary applications of ring construction will be in Structures of smaller diameter. The possibilities of ring construction in onsite assembly of undersea laboratories and in oceanographic research vehicles have already been mentioned. In addition, the technique can find military applications for deep-running-torpedo housings or for submerged missile-silos. SUMMARY 1. A submarine pressure hull built of separate rings may be so deSigned as to have a hydrostatic collapse strength comparable to that of a monolithic hull. 2. The technique of ring construction permits an increase in static collapse strength compared to current steel hulls of the same weight, through the use of light, high-strength, nonweldable materials. This technique may also result in savings in fabrication and assembly costs, which would make it practical for use with weldable materials. 3. A wide variety of mechanical techniques is available to provide the necessary longitudinal strength, watertight integrity, and corrosion protection for hulls of ring construction. The expanding technology of epoxy plastics may provide materials suitable for these applications. RECOMMENDATIONS Future research should include studies of the effects of hull bending moments and longitudinal tensile loads on various types of mechanical joints. ACKNOWLEDGMENTS The author wishes to acknowledge the assistance of Mr. Martin A. Krenzke who initiated the project and designed Models PJ-1S and PJ-1L. REFERENCES 1. U. S. Patent 3,029,966 (April 7, 1962), Reynolds, J. L., "Sub- mersible Pressure Vessel." 2. Walsh, J. B., "Strength of the ALUMINAUT Hull,™ Woods Hole Oceanographic Institute, Ref. No. 62-32 (Apr 1962). 3. Krenzke, M. A. and Kiernan, T. J., "Structural Development of a Titanium Oceanographic Vehicle of Operating Depths of 15,000 to 20,000 Feet," David Taylor Model Basin Report 1677. 4. Pulos, John G., "Structural Analysis and Design Considerations for Cylindrical Pressure Hulls," David Taylor Model Basin Report 1639 (Apr 1963). 5. Short, R. D. Jr., "Membrane Design for Stiffened Cylindrical Shells under Uniform Pressure," David Taylor Model Basin Report (in preparation). 6. Salerno, V. L. and Pulos, J. G., "Stress Distribution in a Circular Cylindrical Shell under Hydrostatic Pressure," Polytechnic Institute of Brooklyn Aeronautical Laboratory Report No. 171-A (1951). 7. Lunchick, M. E. and Short, R. D., Jr., "Behavior of Cylinders with Initial Shell Deflection," David Taylor Model Basin Report 1150 (July 1957). 8. Reynolds, T. E., "Inelastic Lobar Buckling of Cylindrical Shells under External Hydrostatic Pressure," David Taylor Model Basin Report 1392 (Aug 1960). 9. Lunchick, M. E., “Plastic Axisymmetric Buckling of Ring-Stiffened Cylindrical Shells Fabricated from Strain-Hardening Materials and Subjected to External Hydrostatic Pressure," David Taylor Model Basin Report 1393 (Jan 1961). 10. Lunchick, M. E., "Graphical Methods for Determining the Plastic Shell Buckling Pressures of Ring-Stiffened Cylinders Subjected to External Hydrostatic Pressure," David Taylor Model Basin Report 1437 (Mar 1961). 10 11. Hom, K. and Blumenberg, W. F., "Hydrostatic Tests* of Structural Models for Preliminary Design of a Web-Stiffened Sandwich Pressure Hull," David Taylor Model Basin Report 1763, September 1963. 12. Picard, J. and Dietz, R. S., "Seven Miles Down," Putnam, 1961. 11 Figure 1 = Models before Test PSD 307141 Figure la - Model PJ=1S PSD 3 Pisire blble Modeieps=in aye ale ‘PSD 310594 Figure lc - Model PJ-2 PSD 310595 Figure 1d - Model PJ-2 (Showing Rings) Ly) € €. Figure 3b - Model PJ-LL @ Circumferential location of gages pb Circumferential strain sensitivity in win/in per psi & Longitudinal strain sensitivity in yin/in per psi 16 Outside S 3 us ° e (o) io) U 1 @ AT N Ww ~~. O WO] oO WO ° ° ° ° w io) (eo) ft Ti [ [ o} olol/ol/o|l/ol/olojo sa) AI/M/olal+/el/o]™ SIAIAINI ANI ANI MI] ™ (00) WO w w [o) ) 11S) |] SV] S|, OS |] S|, O || © ~ N}O}@O;Aali +t] helo; ™ ral || Gal |) tal |) SGT || GATT] ed |] ed) Figure 3c - Model PJ-2 Q Circumferential location of gages sitivity in pin/in per psi Ey Longitudinal strain sensitivity in win/in per psi &p Circumferential strain sen 7 ‘PSD 310904 Figure 4b - Model PJ-2 sel Figure 4 = Models After Test 18 JACKET So Nn EE ONENESS Mp PLY LU ZZ YM, “CZ ) Figure 5f - Self-Locking MA [— © Figure 5g - ton Figure 5 - Mechanical Joining Techniques 19 TABLE 1 Comparison of Experimental and Theoretical Strain Sensitivities* at Midbay Average PJ-1S | Average PJ-1L _— fs Inside “Strain sensitivities in Win/in/psi. 366 Theoretical Outside Longitudinal Inside Outside “Theory of Salerno and Pulos. fi Bay 2 1/2 only. TABLE 2 Ratios of Theoretical Collapse Pressures to Experimental Collapse Pressures Ratio of Theoretical to Experimental Collapse Pressure Model PJ=-1S Model PJ-1L | Model PJ-2 Theory of Coilapse Modified Tropa Inelastic general instability» (n = 2) Reynolds'* asymmetric clastic” shell buckling Lunchick's atggimatnle” elastic shell ee Pa fa = Lunchick's aiagimasaie ay inelastic shell buckling 20 *Japurp~Ad e9atTUuLyUuT—twes Surpuodsei109 e JOzZ pegnduios Z-fq [epow 1OF sAInssead papeos 008 ‘6 = — 000‘ OST 000‘ 8£T Ojala pl’ Ao Tepow eS eS 000‘ 0ST 00S ‘PrT ¢ OOT‘OT c-£d L2POW ¢ abe tsd ur oinssoid 009 6 00¢ OT asde[Too petess L9 PeTess queod1ed UL OT}eI L9 Tepow quowece Tdstp Tenqov -09-9Y5 TAM tsd ut (qesjzo € 6° 6° 006 °S2 Tepou} ueored 70) Tenqoy | ygsuetzs PTety P ‘ tsd ut ainssead 007° ZL 00S “CT asdeT[oo Tejuowrisedxy ed-AUSC TSPOW | TI-fd TSPOW || SI-fd TSPOW CEST EC ME soinsseig esdepTpop odéjoj01g pue Tequowtusedxy € WIavl 21 AY mak NY sys Pesnabiivioa ‘ Pe ii Aint A TA Le tay My ul q it Re iol # ihisy Pin acai tt My) CU AF alin Fae a FAME Aa INITIAL DISTRIBUTION Copies Copies 15 CHBUSHIPS 1 Dr. E. 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