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Nettles, Alan T.

Publications and source records attributed to Nettles, Alan T..

At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Some Examples of the Relations Between Processing and Damage Tolerance

Most structures made of laminated polymer matrix composites (PMCs) must be designed to some damage tolerance requirement that includes foreign object impact damage. Thus from the beginning of a part s life, impact damage is assumed to exist in the material and the part is designed to carry the required load with the prescribed impact damage present. By doing this, some processing defects may automatically be accounted for in the reduced design allowable due to these impacts. This paper will present examples of how a given level of impact damage and certain processing defects affect the compression strength of a laminate that contains both. Knowledge of the impact damage tolerance requirements, before processing begins, can broaden material options and processing techniques since the structure is not being designed to pristine properties.

Nettles, Alan T.↗
NASA NTRS2011

Low Velocity Impact Damage to Carbon/Epoxy Laminates

Impact damage tends to be more detrimental to a laminate's compression strength as compared to tensile strength. Proper use of Non Destructive Evaluation (NDE) Techniques can remove conservatism (weight) from many structures. Test largest components economically feasible as coupons. If damage tolerance is a driver, then consider different resin systems. Do not use a single knockdown factor to account for damage.

Nettles, Alan T.↗
NASA NTRS2011

Comparison of Open-Hole Compression Strength and Compression After Impact Strength on Carbon Fiber/Epoxy Laminates for the Ares I Composite Interstage

Notched (open hole) composite laminates were tested in compression. The effect on strength of various sizes of through holes was examined. Results were compared to the average stress criterion model. Additionally, laminated sandwich structures were damaged from low-velocity impact with various impact energy levels and different impactor geometries. The compression strength relative to damage size was compared to the notched compression result strength. Open-hole compression strength was found to provide a reasonable bound on compression after impact.

Hodge, Andrew J.↗
NASA NTRS2009

Damage Tolerance of Composite Laminates from an Empirical Perspective

Damage tolerance consists of analysis and experimentation working together. Impact damage is usually of most concern for laminated composites. Once impacted, the residual compression strength is usually of most interest. Other properties may be of more interest than compression (application dependent). A damage tolerance program is application specific (not everyone is building aircraft). The "Building Block Approach" is suggested for damage tolerance. Advantage can be taken of the excellent fatigue resistance of damaged laminates to save time and costs.

Nettles, Alan T.↗
NASA NTRS2009

Hot/Wet Open Hole Compression Strength of Carbon/Epoxy Laminates for Launch Vehicle Applications

This Technical Memorandum examines the effects of heat and absorbed moisture on the open hole compression strength of carbon/epoxy laminates with the material and layup intended for the Ares I composite interstage. The knockdown due to temperature, amount of moisture absorbed, and the interaction between these two are examined. Results show that temperature is much more critical than the amount of moisture absorbed. The environmental knockdown factor was found to be low for this material and layup and thus obtaining a statistically significant number for this value needs to be weighed against a program s cost and schedule since basis values, damage tolerance, and safety factors all contribute much more to the overall knockdown factor.

Nettles, Alan T.↗
NASA NTRS2008

Compression After Impact Testing of Sandwich Structures Using the Four Point Bend Test

For many composite laminated structures, the design is driven by data obtained from Compression after Impact (CAI) testing. There currently is no standard for CAI testing of sandwich structures although there is one for solid laminates of a certain thickness and lay-up configuration. Most sandwich CAI testing has followed the basic technique of this standard where the loaded ends are precision machined and placed between two platens and compressed until failure. If little or no damage is present during the compression tests, the loaded ends may need to be potted to prevent end brooming. By putting a sandwich beam in a four point bend configuration, the region between the inner supports is put under a compressive load and a sandwich laminate with damage can be tested in this manner without the need for precision machining. Also, specimens with no damage can be taken to failure so direct comparisons between damaged and undamaged strength can be made. Data is presented that demonstrates the four point bend CAI test and is compared with end loaded compression tests of the same sandwich structure.

Nettles, Alan T.↗
NASA NTRS2006

Mode I Toughness Measurements of Core/Facesheet Bonds in Honeycomb Sandwich Structures

Composite sandwich structures will be used in many future applications in aerospace, marine and offshore industries due to the fact that the strength and stiffness to mass ratios surpass any other structural type. Sandwich structure also offers advantages over traditional stiffened panels such as ease of manufacturing and repair. During the last three decades, sandwich structure has been used extensively for secondary structure in aircraft (fuselage floors, rudders and radome structure). Sandwich structure is also used as primary structure in rotorcraft, the most common example being the trailing edge of rotor blades. As with other types of composite construction, sandwich structure exhibits several types of failure mode such as facesheet wrinkling, core crushing and sandwich buckling. Facesheet/core debonding has also been observed in the marine and aerospace industry. During this failure mode, peel stresses applied to an existing facesheet/core debond or an interface low in toughness, results in the facesheet being peeled from the core material, possibly leading to a significant loss in structural integrity of the sandwich panel. In an incident during a test on a liquid hydrogen fuel tank of the X-33 prototype vehicle, the outer graphite/epoxy facesheet and honeycomb core became debonded from the inner facesheet along significant areas, leading to failure of the tank. As a consequence of the accident; significant efforts were made to characterize the toughness of the facesheet/core bond. Currently, the only standardized method available for assessing the quality of the facesheet/core interface is the climbing drum peel test (ASTM D1781). During this test a sandwich beam is removed from a panel and the lip of one of the facesheets is attached to a drum, as shown in Fig. 1. The drum is then rotated along the sandwich beam, causing the facesheet to peel from the core. This method has two major drawbacks. First, it is not possible to obtain quantitative fracture data from the test and so the results can only be used in a qualitative manner. Second, only sandwich structure with thin facesheets can be tested (to facilitate wrapping of the facesheet around the climbing drum). In recognition of the need for a more quantitative facesheet/core fracture test, several workers have devised experimental techniques for characterizing the toughness of the facesheet/core interface. In all of these cases, the tests are designed to yield a mode I-dominated fracture toughness of the facesheet/core interface in a manner similar to that used to determine mode I fracture toughness of composite laminates. In the current work, a modified double cantilever beam is used to measure the mode I-dominated fracture toughness of the interface in a sandwich consisting of glass/phenolic honeycomb core reinforced with graphite epoxy facesheets. Two specimen configurations were tested as shown in Fig 2. The first configuration consisted of reinforcing the facesheets with aluminum blocks (Fig. 2a). In the second configuration unreinforced specimens were tested (Fig. 2b). Climbing drum peel tests were also conducted to compare the fracture behavior observed between this test and the modified double cantilever beam. This paper outlines the test procedures and data reduction strategies used to compute fracture toughness values from the tests. The effect of specimen reinforcement on fracture toughness of the facesheet/core interface is discussed.

Nettles, Alan T.↗
NASA NTRS2004

Allowables for Structural Composites

In order to obtain the most benefit from building a structure with composite laminates, the strength of the laminate must be known. Based on the "weakest link" theory, the lower strength numbers obtained from testing are the ones to be used for design and analysis. The strength value to be used is determined by a statistical analysis of the test data, and is known as an allowable. MIL-HDBK- 17 outlines procedures to follow for determining these allowables. There are two types of statistically determined allowables, A- Basis and B-Basis. A-Basis is defined as a strength value at which only 1 in 100 specimens will fail with a 95% confidence level. B-Basis is a strength value at which only 10 in 100 specimens will fail with a 95% confidence level. As more specimens are tested a higher value of strength can be used as a valid allowable. Composites are highly process dependent and show much strength variation with environment, so it is critical to test materials and environments that are representative of hardware. Either using data obtained from a previous test series, or extrapolation to a certain temperature is highly discouraged.

Nettles, Alan T.↗
NASA NTRS2003

Polymer Matrix Composites for Propulsion Systems

The Access-to-Space study identified the requirement for lightweight structures to achieve orbit with a single-stage vehicle. Thus a task was undertaken to examine the use of polymer matrix composites for propulsion components. It was determined that the effort of this task would be to extend previous efforts with polymer matrix composite feedlines and demonstrate the feasibility of manufacturing large diameter feedlines with a complex shape and integral flanges, (i.e. all one piece with a 90 deg bend), and assess their performance under a cryogenic atmosphere.

Nettles, Alan T.↗
NASA NTRS2003

Lifetime Predictions of a Titanium Silicate Glass with Machined Flaws

A dynamic fatigue study was performed on a Titanium Silicate glass to assess its susceptibility to delayed failure and to compare the results with those of a previous study. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions. The material strength and lifetime was seen to increase due to the removal of residual stress through grinding and polishing. Influence on time-to-failure is addressed for the case with and without residual stress present. Titanium silicate glass otherwise known as ultra-low expansion (ULE)* glass is a candidate for use in applications requiring low thermal expansion characteristics such as telescope mirrors. The Hubble Space Telescope s primary mirror was manufactured from ULE glass. ULE contains 7.5% titanium dioxide which in combination with silica results in a homogenous glass with a linear expansion coefficient near zero. delayed failure . This previous study was based on a 230/270 grit surface. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing the material with successively smaller grinding media. This results in an increase in strength of the optic during the grinding and polishing sequence. Thus, a second study was undertaken using samples with a surface finish typically achieved for mirror elements, to observe the effects of surface finishing on the time-to-failure predictions. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure, most likely due to stress corrosion, which can significantly shorten lifetime. Fortunately, a theory based on fracture mechanics has been developed enabling lifetime predictions to be made for brittle materials susceptible to delayed failure. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct a time-to-failure diagram for polished ULE glass.

Tucker, Dennis S.↗
NASA NTRS2003

Permeability After Impact Testing of Composite Laminates

Since composite laminates are beginning to be identified for use in reusable launch vehicle propulsion systems, an understanding of their permeance is needed. A foreign object impact event can cause a localized area of permeability (leakage) in a polymer matrix composite and it is the aim of this study to assess a method of quantifying permeability-after-impact results. A simple test apparatus is presented and variables that could affect the measured values of permeability-after-impact were assessed. Once it was determined that valid numbers were being measured, a fiber/resin system was impacted at various impact levels and the resulting permeability measured, first with a leak check solution (qualitative) then using the new apparatus (quantitative). The results showed that as the impact level increased, so did the measured leakage. As the pressure to the specimen was increased, the leak rate was seen to increase in a non-linear fashion for almost all of the specimens tested.

Nettles, Alan T.↗
NASA NTRS2002

Dynamic Fatigue of a Titanium Silicate Glass

A dynamic fatigue study was performed on a Titanium Silicate Glass in order to assess its susceptibility to delayed failure. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions for optical elements made from this material. The material has reasonably good resistance (N=23 to stress corrosion in ambient conditions).

Tucker, Dennis S.↗
NASA NTRS2001

A Comparison of Quasi-Static Indentation Testing to Low Velocity Impact Testing

The need for a static test method for modeling low-velocity foreign object impact events to composites would prove to be very beneficial to researchers since much more data can be obtained from a static test than from an impact test. In order to examine if this is feasible, a series of static indentation and low velocity impact tests were carried out and compared. Square specimens of many sizes and thickness were utilized to cover the array of types of low velocity impact events. Laminates with a n/4 stacking sequence were employed since this is by the most common type of engineering laminate. Three distinct flexural rigidities under two different boundary conditions were tested in order to obtain damage due to large deflections, contact stresses and both to examine if the static indentation-impact comparisons are valid under the spectrum of damage modes that can be experienced. Comparisons between static indentation and low velocity impact tests were based on the maximum applied transverse load. The dependent parameters examined included dent depth, back surface crack length, delamination area and to a limited extent, load-deflection behavior. Results showed that no distinct differences could be seen between the static indentation tests and the low velocity impact tests, indicating that static indentation can be used to represent a low velocity impact event.

Nettles, Alan T.↗
NASA NTRS2001

Permeability Testing of Impacted Composite Laminates for Use on Reusable Launch Vehicles

Since composite laminates are beginning to be identified for use in reusable launch vehicle propulsion systems, an understanding of their permeance is needed. A foreign object impact event can cause a localized area of permeability (leakage) in a polymer matrix composite, and it is the aim of this study to assess a method of quantifying permeability-after-impact results. A simple test apparatus is presented, and variables that could affect the measured values of permeability-after-impact were assessed. Once it was determined that valid numbers were being measured, a fiber/resin system was impacted at various impact levels and the resulting permeability measured, first with a leak check solution (qualitative) then using the new apparatus (quantitative). The results showed that as the impact level increased, so did the measured leakage. As the pressure to the specimen was increased, the leak rate was seen to increase in a nonlinear fashion for almost all the specimens tested.

Nettles, Alan T.↗
NASA NTRS2001

Dynamic Fatigue of ULE Glass

Ultra Low Expansion (ULE) glass is used in a number of applications which require a low thermal expansion coefficient. One such application is telescope mirror elements. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure. Delayed failure, due to stress corrosion can significantly shorten the lifetime of a glass article. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct time-to-failure diagrams for both 230/270 ground and optically polished samples. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing materials with successively smaller grinding media. This resulted in an increase in the strength of the optic during the grinding and polishing sequence. There was also an increase in the lifetime due to grinding and polishing. It was found that using the fatigue parameters determined from the 230/270 grit surface are not significantly different from the optically polished values. Although the lower bound of the polished samples is more conservative, neither time-to-failure curves lie beyond the upper or lower bound of the confidence limits. Therefore, designers preferring conservative limits could use samples without residual stress present (polished samples) to determine the fatigue parameters and inert Weibull parameters from samples with the service condition surface, to determine time-to-failure of the optical element.

Tucker, Dennis S.↗
NASA NTRS2001

Infrared Fibers for Use in Space-Based Smart Structures

Infrared optical fibers are finding a number of applications including laser surgery, remote sensing, and nuclear radiation resistant links. Utilizing these fibers in space-based structures is another application, which can be exploited. Acoustic and thermal sensing are two areas in which these fibers could be utilized. In particular, fibers could be embedded in IM7/8552 toughened epoxy and incorporated into space structures both external and internal. ZBLAN optical fibers are a candidate, which have been studied extensively over the past 20 years for terrestrial applications. For the past seven years the effects of gravity on the crystallization behavior of ZBLAN optical fiber has been studied. It has been found that ZBLAN crystallization is suppressed in microgravity. This lack of crystallization leads to a fiber with better transmission characteristics than its terrestrial counterpart.

Tucker, Dennis S.↗
NASA NTRS2001

X-33 Tank Failure During Autoclave Fabrication

The composite liquid hydrogen tank (tank #1 of 2) for the X-33 flight vehicle is made up of four lobes that have a sandwich construction, bonded to a frame of longerons. Lobes 1 and 4 showed local disbonds to the longerons they were bonded to. The 'bad' areas were cut away and patched with new material. The new material was cured by placing the entire tank in a heated autoclave with no pressure. Upon removal from the autoclave, it was noted that lobe 1 had severe skin/core disbonds on the inner and outer skins. The skins on this lobe were cracked as well. The core was disbonded from the inner skin across the entire acreage, except for spots around the lobe perimeter. The outer skin was separated from the core in a region near the center of the lobe. Lobe 1 was removed from the tank on January 13, 1999. Bolts were placed through the lobe to hold it together and the cuts on the inner skin were not continuous, but 'tabs' were left for final cutting and removal. Upon closer inspection of the disbonded basesheet, it was noted that there was a lack of filleting into the honeycomb core. Good fillets are critical to bond strength.

Nettles, Alan T.↗