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Ronald Krueger

Publications and source records attributed to Ronald Krueger.

17 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Advances in Thermoplastic Composites Over Three Decades – A Literature Review

Recently, there has been a renewed interest in thermoplastic composites driven mainly by advances in automation which can lead to significant cost reductions by increasing manufacturing rates while simultaneously reducing the part count and energy consumption relative to the manufacturing of thermoset composites. At the same time, new material systems have been developed and the thermoplastic composites prepreg material quality has improved over time. Additionally, thermoplastic composites have nearly infinite room-temperature shelf life and production scraps can be reused and retired parts can be recycled, providing opportunities for more sustainable operations and downstream markets. These factors have contributed to a strong interest in advancing thermoplastic composites for aerospace, automotive, and other industrial applications. The objective of the present study is to assess the state of the art regarding the maturity and performance of thermoplastic composite materials and to document the advances made in manufacturing and assembly of thermoplastic composite structures. Therefore, more than 200 NASA reports, conference proceedings and journal papers spanning three and a half decades (1986-2022) were reviewed and the findings summarized. The current study, however, is limited in scope with a focus on the application of thermoplastic composites to aircraft structures. Further, the study does not provide a comprehensive assessment of the available literature but rather offers an overview of past and present research being conducted in the field of thermoplastic composites. The information provided may be used to identify gaps and help guide future research and development. In this report, the opportunities offered by the use of thermoplastic composites in general and challenges encountered in particular are presented first. Second, an overview of thermoplastic materials is presented, manufacturing methods are discussed, and new methods for fastener-less assembly such as welding are introduced. Third, tests that have been performed on different levels of the building block, ranging from coupon to structural level, are presented. In particular, fracture toughness results for different thermoplastic composite materials are used to demonstrate their performance compared to state-of-the-art thermoset composites. Fourth, several examples of analyses are discussed including process modelling and progressive damage analysis (PDA). An extensive list of references and appendices with tables support the narrative. Lastly, a brief summary with outlook and recommendations for future research is provided.

composites↗
NASA NTRS2024

Characterizing Face Sheet/Core Disbonding Using the Single Cantilever Beam Test: Results from an International Round Robin

Test results from an international round robin are presented. The single cantilever beam (SCB) test was used to characterize face sheet/core disbonding in sandwich components in an effort to help standardization. Each of the seven participating laboratories performed a set of five baseline tests using the same protocol, however, using their own specific equipment. In addition, each laboratory performed two sets of tests with altered tests conditions which included using a test fixture with a translating carriage and performing the tests with different loading and unloading speeds. The orientation of the disbond front with respect to the honeycomb core cells was varied and the effect on the fracture toughness was also studied. Additional factors that could influence test results were investigated, such as the use of a saw cut starter disbond as an alternative to Teflon® release film, and the effects of using a face sheet doubler to increase the bending stiffness. For each set of tests, summary results such as load/displacements plots, observed disbond growth location and calculated energy release rates are reported and a comparison of results between labs is presented. Critical strain energy release rate measurements from SCB tests are also compared with measurements made from an alternative test, namely the double cantilever beam with uneven bending moments (DCB-UBM) test, which has been studied extensively at the Technical University of Denmark and proposed as a mixed-mode test standard. A set of recommendations are made with respect to improving the SCB test and a path to standardization is presented.

Ronald Krueger↗
NASA NTRS2022

A Benchmark Example for Delamination Propagation Predictions Based on the Calibrated End-Loaded Split Specimen

A benchmark example based on the Calibrated End-Loaded Split (C-ELS) specimen is developed and used to assess the performance of recently developed delamination propagation capabilities in the Abaqus/Standard finite element code. The C-ELS specimen has the advantage of a longer region of stable delamination propagation compared to the existing mode II benchmark case. The new benchmark example may therefore provide a better assessment tool by enabling more stable crack growth in regions further away from the boundary conditions or load application. First, a benchmark result is created manually using two-dimensional finite element models of the C-ELS specimen with different delamination lengths. Second, the performance of the delamination propagation capabilities in the Abaqus/Standard finite element code are assessed by comparing the results to the benchmark case. Two examples with different starter delamination lengths are studied. A shorter starter length is chosen to create a scenario with unstable delamination propagation. A longer delamination causes stable delamination propagation. Detailed results from three-dimensional analyses with aligned and mis-aligned meshes and two levels of mesh refinement are provided for several permutations of numerical input parameters. In general, good agreement can be achieved between the results obtained from the quasi-static propagation analysis and the benchmark analysis. However, particular non-default settings are found to be most reliable, accurate, and numerically efficient. Numerical artifacts including anomalous unreleased nodes in the crack wake and zig-zag crack fronts occur, and further development of the Abaqus/Standard VCCT propagation may be required. Use of the benchmark case to assess the continuous improvements in one finite element code illustrates the value of establishing benchmark solutions.

delamination↗
NASA NTRS2020

DEVELOPMENT AND APPLICATION OF BENCHMARK EXAMPLES FOR MIXED-MODE I/II FATIGUE GROWTH PREDICTIONS

The development of benchmark examples for assessing growth prediction capabilities is presented and demonstrated for a commercial code. The examples are based on finite element models of Mixed-Mode Bending (MMB) specimens for three different mode ratios. The examples are independent of the analysis software used and allow the assessment of the automated delamination propagation, onset and growth prediction capabilities in commercial finite element codes based on the virtual crack closure technique (VCCT). First, based on existing results for delamination propagation under static loading, new benchmark examples for delamination growth under fatigue loading were created. Second, starting from an initially straight front, the delamination was allowed to grow under fatigue loading. The number of cycles to delamination onset and the number of cycles during delamination growth for each growth increment were obtained from the automated analysis and compared to the benchmark examples. Good agreement between the results obtained from the growth analysis and the benchmark results could be achieved by selecting the appropriate input parameters. The benchmarking procedure proved valuable by highlighting the issues associated with choosing the input parameters of the particular implementation. Overall the results from automatic propagation are encouraging, however, selecting the appropriate input parameters was not straightforward and often required an iterative procedure.

Composites↗
NASA NTRSDate not supplied

A Benchmark Example for Delamination Propagation Predictions Based on the Single Leg Bending Specimen under Quasi-static and Fatigue Loading

Benchmark examples based on Single Leg Bending (SLB) specimens with equal and unequal bending arm thicknesses were used to assess the performance of delamination prediction capabilities in finite element codes. First, the development of the quasi-static benchmark cases using the Virtual Crack Closure Technique (VCCT) is discussed in detail. Second, based on the quasi-static benchmark results, additional benchmark cases to assess delamination propagation under fatigue loading are created. Third, the application is demonstrated for the commercial finite element code Abaqus Standard 2018. The benchmark cases are compared to results obtained from VCCT-based, automated quasi-static propagation analysis. A comparison with results from automated fatigue propagation analysis was not performed at this point since the current version of Abaqus does not include this capability under variable mixed-mode conditions. In general, good agreement between the results obtained from the quasi-static propagation analysis and the benchmark results were achieved. Overall, the benchmarking procedure proved valuable for analysis verification.

Ronald Krueger↗
NASA NTRSDate not supplied

An Investigation on the Accuracy of Delamination Analysis Predictions for Unidirectional Laminate Configurations

The state-of-the-art methodologies for predicting delamination growth in composite laminates make use of the concept of mixed-mode fracture mechanics. In mixed-mode fracture approaches the individual Mode I, Mode II and Mode III components of the strain energy release rate (SERR) need to be determined under general loading conditions. Through the use of mixed-mode fracture, the individual components are used in combination with the critical strain energy release rates (interlaminar fracture toughnesses) for each fracture mode in a mixed mode criterion in order to predict delamination extension. These interlaminar fracture toughnesses are traditionally obtained by testing of unidirectional laminate coupons. This work presents an investigation on the accuracy of Double Cantilever Beam (DCB), End Notch Flexure (ENF) and Mixed-Mode Bending (MMB) delamination analysis predictions by comparing measured total strain-energy release rates obtained experimentally to results for structural analysis from closed-form expressions, shell finite element analysis, and continuum two-dimensional (2D) and three-dimensional (3D) (solid) finite element analysis.

Patrick Enjuto↗
NASA NTRSDate not supplied

TPSAS-NF1676L-13122-DND

An approach for assessing the delamination propagation and growth capabilities in commercial finite element codes was developed and demonstrated for the Virtual Crack Closure Technique (VCCT) implementations in ABAQUS?. The Double Cantilever Beam (DCB) specimen was chosen as an example. First, benchmark results to assess delamination propagation capabilities under static loading were created using models simulating specimens with different delamination lengths. Second, starting from an initially straight front, the delamination was allowed to propagate based on the algorithms implemented in the commercial finite element software. The load-displacement relationship obtained from the propagation analysis results and the benchmark results were compared. Good agreements could be achieved by selecting the appropriate input parameters, which were determined in an iterative procedure. A benchmark case to assess the fatigue growth prediction capabilities was also created. Input control parameters were varied to study the effect on the computed delamination growth. The benchmarks enabled the selection of the appropriate input parameters that yielded good agreements between the results obtained from the automated analysis and the benchmark results. Overall, the results are encouraging but further assessment for mixed-mode delamination is required.

Ronald Krueger↗
NASA NTRSDate not supplied

TPSAS-NF1676L-14662-DND

In this presentation, the development of the benchmark cases for the assessment of the static delamination propagation as well as the onset and growth prediction capabilities are presented. Examples of automated propagation and growth analyses are shown with a focus on mode II fracture and the simulation of the three-point bending End Notched Flexure (ENF) specimen. Further the selection of the required code specific input parameters are discussed. The current capabilities are summarized while remaining difficulties and future challenges are also highlighted.

Ronald Krueger↗
NASA NTRSDate not supplied

Validation of Delamination Growth Predictions under Fatigue Loading using the Single Leg Bending Specimen

The Single Leg Bending Specimen (SLB) was chosen for a study to compare experimentally determined delamination growth with analysis predictions. First, fatigue tests were performed on SLB specimens with several different starter delamination lengths. Specimens were cycled in load control and delamination length increase was continuously recorded with increasing number of cycles. Test results from different load levels were combined to capture the entire delamination growth law (Paris Law) over a wide range of energy release rates. Second, a recently developed interpolation scheme was used to predict the Paris Law associated with the SLB specimen. This interpolation scheme allows the calculation of the growth rates for a given mixed-mode ratio from known single-mode growth laws. Third, finite element analyses were performed using two-dimensional models of the SLB specimen. New Virtual Crack Closure Technique based analysis tools for automated delamination growth analysis under cyclic loading in Abaqus were used for growth predictions. Fourth, the predictions from analyses were compared to experimental fatigue data. Remaining analysis shortcomings were highlighted.

Ronald Krueger↗
NASA NTRSDate not supplied

Development of a C-ELS Specimen-Based Numerical Benchmark for Mode II Delamination and Assessment of Two VCCT-Based Propagation Strategies

A finite element (FE) benchmark example inspired by the calibrated end-loaded split (C-ELS) specimen is developed and used to assess the performance of delamination propagation capabilities based on linear elastic fracture mechanics (LEFM). The C-ELS specimen has the advantage of a longer region of stable delamination propagation compared to the existing mode II benchmark case. The new benchmark example may therefore provide a better assessment tool by enabling more stable crack growth in regions further away from the boundary conditions or load application. First, a benchmark result is created manually using two-dimensional finite element models of the C-ELS specimen with different delamination lengths. Second, the performance of the virtual crack closure technique (VCCT) delamination propagation capabilities in the Abaqus/Standard®1 FE code and the recently developed Progressive Release eXplicit-VCCT (PRX-VCCT) method are assessed by comparing the results to the benchmark case. Two examples with different starter delamination lengths are studied. A shorter starter length is chosen to create a scenario with unstable delamination propagation. A longer delamination encourages stable delamination propagation. Detailed results from three-dimensional analyses with aligned and misaligned meshes and two levels of mesh refinement are provided. In general, good agreement can be achieved between the results obtained from the quasi-static propagation analysis and the benchmark analysis. Numerical artifacts including anomalous unreleased nodes in the crack wake and zig-zag crack fronts occur for propagation analyses using Abaqus/Standard VCCT. In comparison, continuous, smooth, delamination fronts are observed for PRX-VCCT. The use of the benchmark case to assess different VCCT-based propagation strategies illustrates the value of establishing benchmark cases.

Composite Materials↗
NASA NTRSDate not supplied

Interlaminar R-Curve Effects in Thermoplastic Composites: Experiments and Model Correlations

The interlaminar fracture behavior of thermoplastic composites under Mode-I and Mode-II static loading is investigated in this research. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK)†. Characterization experiments were conducted to measure the load-displacement response, peak load, and propagation of delamination from a pre-implanted Kapton® insert. The Mode-I response was characterized using a double cantilever beam (DCB) test according to the ASTM D5528-22 standard. It was observed that the propagation exhibited significant resistance to delamination growth, i.e., an R-Curve effect. The test data indicated that the steady-state fracture toughness, G SS I , was approximately twice the mean initiation fracture toughness, G Ic . The Mode-II response of an end notch flexure (ENF) specimen tested according to the ASTM D7905-19 standard exhibited an unexpected stable behavior upon attaining peak load. Prior to attaining peak load, the Mode-II response exhibited some non-linearity, which may be attributed to nonlinear bulk material response, e.g., hyper-elasticity, viscoelasticity, plasticity, etc., and potentially friction at the load/support rollers and R-Curve effects. Finite element models based on the Cohesive Zone Method (CZM) and the Virtual Crack Closure Technique (VCCT) were used to predict the DCB and ENF specimen responses. DCB analysis results obtained using G SS I predicted propagation consistent with experimental data. However, results obtained with the as characterized G Ic were inaccurate in predicting delamination growth onset and peak load. ENF analysis results obtained with the as-characterized Mode-II fracture toughness, G IIc , were inaccurate in predicting the peak load and propagation. Hence, R-Curve effects were included in both DCB and ENF simulations, which enabled improved predictions. The experimentally determined Mode-I R-Curve was used for the DCB simulations, whereas an R-Curve was derived for Mode-II assuming that the change in compliance of the specimen was associated with crack growth only.

Prabhakar M Rao↗
NASA NTRSDate not supplied

Interlaminar R-Curve Effects in Thermoplastic Composites: Experiments and Model Correlations

The interlaminar fracture behavior of thermoplastic composites under Mode-I and Mode-II static loading is investigated in this research. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK)†. Characterization experiments were conducted to measure the load-displacement response, peak load, and propagation of delamination from a pre-implanted Kapton® insert. The Mode-I response was characterized using a double cantilever beam (DCB) test according to the ASTM D5528-22 standard. It was observed that the propagation exhibited significant resistance to delamination growth, i.e., an R-Curve effect. The test data indicated that the steady-state fracture toughness, G SS I , was approximately twice the mean initiation fracture toughness, G Ic . The Mode-II response of an end notch flexure (ENF) specimen tested according to the ASTM D7905-19 standard exhibited an unexpected stable behavior upon attaining peak load. Prior to attaining peak load, the Mode-II response exhibited some non-linearity, which may be attributed to nonlinear bulk material response, e.g., hyper-elasticity, viscoelasticity, plasticity, etc., and potentially friction at the load/support rollers and R-Curve effects. Finite element models based on the Cohesive Zone Method (CZM) and the Virtual Crack Closure Technique (VCCT) were used to predict the DCB and ENF specimen responses. DCB analysis results obtained using G SS I predicted propagation consistent with experimental data. However, results obtained with the as characterized G Ic were inaccurate in predicting delamination growth onset and peak load. ENF analysis results obtained with the as-characterized Mode-II fracture toughness, G IIc , were inaccurate in predicting the peak load and propagation. Hence, R-Curve effects were included in both DCB and ENF simulations, which enabled improved predictions. The experimentally determined Mode-I R-Curve was used for the DCB simulations, whereas an R-Curve was derived for Mode-II assuming that the change in compliance of the specimen was associated with crack growth only.

Prabhakar Rao↗