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NASA NTRS1989

Thermo-viscoelastic analysis of composite materials

The thermo-viscoelastic boundary value problem for anisotropic materials is formulated and a numerical procedure is developed for the efficient analysis of stress and deformation histories in composites. The procedure is based on the finite element method and therefore it is applicable to composite laminates containing geometric discontinuities and complicated boundary conditions. Using the present formulation, the time-dependent stress and strain distributions in both notched and unnotched graphite/epoxy composites have been obtained. The effect of temperature and ply orientation on the creep and relaxation response is also studied.

Lin, Kuen Y.↗

NASA NTRS1990

Lightweight, Thermally Conductive Composite Material

Aluminum reinforced with carbon fibers superior to copper in some respects. Lightweight composite material has high thermal conductivity. Consists of aluminum matrix containing graphite fibers, all oriented in same direction. Available as sheets, tubes, and bars. Thermal conductivity of composite along fibers rises above that of pure copper over substantial range of temperatures. Graphite/aluminum composite useful in variety of heat-transfer applications in which reduction of weight critical. Used to conduct heat in high-density, high-speed integrated-circuit packages for computers and in base plates for electronic equipment. Also used to carry heat away from leading edges of wings in high-speed airplanes.

Sharp, G. Richard↗

NASA NTRS1990

COMGEN: A computer program for generating finite element models of composite materials at the micro level

COMGEN (Composite Model Generator) is an interactive FORTRAN program which can be used to create a wide variety of finite element models of continuous fiber composite materials at the micro level. It quickly generates batch or session files to be submitted to the finite element pre- and postprocessor PATRAN based on a few simple user inputs such as fiber diameter and percent fiber volume fraction of the composite to be analyzed. In addition, various mesh densities, boundary conditions, and loads can be assigned easily to the models within COMGEN. PATRAN uses a session file to generate finite element models and their associated loads which can then be translated to virtually any finite element analysis code such as NASTRAN or MARC.

Melis, Matthew E.↗

NASA NTRS1990

Investigation of the reaction kinetics between SiC fibers and selectively alloyed titanium matrix composites and determination of their mechanical properties

During high temperature exposure, an interfacial reaction occurs between SiC fiber reinforcement and titanium matrices which can be detrimental to the mechanical properties of the composite. The reaction kinetics between SCS-6 fibers and Ti-1100 were determined at 800 to 1000 C and found to be slower than those of other currently used titanium alloys (Ti-15-3, Ti-6-4). The experimentally determined reaction kinetics for Ti-1100 were extrapolated to 700 C and found to accurately predict reaction zone size after 1000 hours of exposure. Predictions of the time to consume the surface layer on the SCS-6 and SCS-9 fibers were made in an effort to estimate the time that the fiber will retain its strength in Ti-1100 during isothermal exposure at high temperatures. Using this approach, the strength of an SCS-6 fiber in Ti-1100 should be retained for over 20,000 hours at isothermal exposures less than 800 C. Strength predictions using the rule of mixtures for a unidirectional Ti-1100/SCS-6 composite are presented for short term exposures up to 700 C. Room temperature tests of an as-fabricated 20 volume percent fiber/Ti-1100 composite yielded a UTS of 226 ksi (1490 MPa) which is close to that predicted by the ROM.

Gundel, Douglas B.↗

NASA NTRS1989

Noninteractive macroscopic reliability model for ceramic matrix composites with orthotropic material symmetry

A macroscopic noninteractive reliability model for ceramic matrix composites is presented. The model is multiaxial and applicable to composites that can be characterized as orthotropic. Tensorial invariant theory is used to create an integrity basis with invariants that correspond to physical mechanisms related to fracture. This integrity basis is then used to construct a failure function per unit volume (or area) of material. It is assumed that the overall strength of the composite is governed by weakest link theory. This leads to a Weibull type model similar in nature to the principle of independent action (PIA) model for isotropic monolithic ceramics. An experimental program to obtain model parameters is briefly discussed. In addition, qualitative features of the model are illustrated by presenting reliability surfaces for various model parameters.

Duffy, Stephen F.↗

NASA NTRS1989

Damage-tolerant composite materials produced by stitching carbon fibers

NASA-Langley has undertaken the investigation of composite damage-tolerance enhancement and fabrication economies-maximization via reinforcement-stitching, in combination with resin transfer molding. Attention is given to results obtained by an experimental evaluation of composites tailored for damage tolerance by stitching layers of dry carbon-fiber fabric with closely-spaced threads, in order to furnish through-the-thickness reinforcement. Various stitching patterns and thread materials have been evaluated, using flat-plate specimens; blade-stiffened structural elements have been fabricated and tested. The results presented indicate that stitched laminates furnish damage tolerance performance comparable to that of more expensive, toughened-matrix composites.

Dow, Marvin B.↗

NASA NTRS1990

Reinforcements: The key to high performance composite materials

Better high temperature fibers are the key to high performance, light weight composite materials. However, current U.S. and Japanese fibers still have inadequate high temperature strength, creep resistance, oxidation resistance, modulus, stability, and thermal expansion match with some of the high temperature matrices being considered for future aerospace applications. In response to this clear deficiency, both countries have research and development activities underway. Once successful fibers are identified, their production will need to be taken from laboratory scale to pilot plant scale. In such efforts it can be anticipated that the Japanese decisions will be based on longer term criteria than those applied in the U.S. Since the initial markets will be small, short term financial criteria may adversely minimize the number and strength of U.S. aerospace materials suppliers to well into the 21st century. This situation can only be compounded by the Japanese interests in learning to make commercial products with existing materials so that when the required advanced fibers eventually do arrive, their manufacturing skills will be developed.

Grisaffe, Salvatore J.↗

NASA NTRS1991

Environmental exposure effects on composite materials for commercial aircraft

A study was conducted to determine the effects of long term flight and ground exposure on three commercially available graphite-epoxy material systems: T300/5208, T300/5209, and T300/934. Sets of specimens were exposed on commercial aircraft and ground racks for 1, 2, 3, 5, and 10 years. Inflight specimen sites included both the interior and exterior of aircraft based in Hawaii, Texas, and New Zealand. Ground racks were located at NASA-Dryden and the above mentioned states. Similar specimens were exposed to controlled lab conditions for up to 2 years. After each exposure, specimens were tested for residual strength and a dryout procedure was used to measure moisture content. Both room and high temperature residual strengths were measured and expressed as a pct. of the unexposed strength. Lab exposures included the effects of time alone, moisture, time on moist specimens, weatherometer, and simulated ground-air-ground cycling. Residual strengths of the long term specimens were compared with residual strengths of the lab specimens. Strength retention depended on the exposure condition and the material system. Results showed that composite materials can be successfully used on commercial aircraft if environmental effects are considered.

Hoffman, Daniel J.↗

NASA NTRS1991

The effect of TiB2 reinforcement on the mechanical properties of an Al-Cu-Li alloy-based metal-matrix composite

The addition of ceramic particles to aluminum based alloys can substantially improve mechanical properties, especially Young's modulus and room and elevated temperature strengths. However, these improvements typically occur at the expense of tensile ductility. The mechanical properties are evaluated to a metal matrix composite (MMC) consisting of an ultrahigh strength aluminum lithium alloy, Weldalite (tm) 049, reinforced with TiB2 particles produced by an in situ precipitation technique called the XD (tm) process. The results are compared to the behavior of a nonreinforced Weldalite 049 variant. It is shown that both 049 and 049-TiB2 show very attractive warm temperature properties e.g., 625 MPa yield strength at 150 C after 100 h at temperature. Weldalite 049 reinforced with a nominal 4 v pct. TiB2 shows an approx. 8 pct. increase in modulus and a good combination of strength (529 MPa UTS) and ductility (6.5 pct.) in the T3 temper. And the high ductility of Weldalite 049 in the naturally aged and underaged tempers makes the alloy a good, high strength matrix for ceramic reinforcement.

Source record↗

NASA NTRS1991

Delamination, durability and damage tolerance of laminated composite materials

Research exploring the role of delamination on the durability and damage tolerance of advanced composite materials is reviewed. Recent studies on the characterization of composite delamination are summarized. Recent analytical solutions for interlaminar stresses and strain energy release rates associated with common sources of delamination are also reviewed. The role of delamination in low velocity impact, residual compression strength, and in fatigue is highlighted. Delamination is shown to be the common damage mode observed in all of these problems. A Damage Threshold/Fail-safety concept for addressing composite damage tolerance is discussed.

O'Brien, T. K.↗

NASA NTRS1991

Combustion synthesis of TiB2-Al2O3-Al composite materials

The oxide-aluminum exothermic reduction reaction is presently used in the combustion-synthesis of ceramic/metal composites. An excess of Al is used in the reacting materials, which rapidly generate enough heat to exceed Al's melting point. The molten Al thus evolved is allowed to infiltrate the porous ceramic matrix as the exothermic reaction proceeds; this feature of the process turns the disadvantage of high porosity levels in combustion-synthesized materials into an advantage. Attention is given to the system obtained with 3TiO2 + 3B2O3 + (10-x)Al starting materials.

Feng, H. J.↗

NASA NTRS1992

An enhanced Whipple Bumper system - Impact resistance of composite materials

For long-duration space flights where human occupation is expected, micrometeroid and debris shields are necessary to prevent puncture of the pressure vessels. Current 'Whipple Bumper' designs range from single thin sheets of aluminum to complicated structures of many energy absorbing layers. This paper details the results of an experimental program tao determine the increased protection afforded by intermediate bumpers made of composite material structures. Various configurations of honeycomb support structures sandwiched between layers of materials such as Kevlar, Spectra, aluminum, and others are inserted between the bumper and pressure shell. The areal densities of each new material structure are maintained constant so that the results compare directly with single-sheet aluminum intermediate bumpers.

Zwiener, J.↗

NASA NTRS1991

Nonlinear mechanics of composite materials with periodic microstructure

This report summarizes the result of research done under NASA NAG3-882 Nonlinear Mechanics of Composites with Periodic Microstructure. The effort involved the development of non-finite element methods to calculate local stresses around fibers in composite materials. The theory was developed and some promising numerical results were obtained. It is expected that when this approach is fully developed, it will provide an important tool for calculating local stresses and averaged constitutive behavior in composites. NASA currently has a major contractual effort (NAS3-24691) to bring the approach developed under this grant to application readiness. The report has three sections. One, the general theory that appeared as a NASA TM, a second section that gives greater details about the theory connecting Greens functions and Fourier series approaches, and a final section shows numerical results.

Jordan, E. H.↗

NASA NTRS1991

Effects of intra- and inter-laminar resin content on the mechanical properties of toughened composite materials

Composite materials having multiphase toughened matrix systems and laminate architectures characterized by resin-rich interlaminar layers (RIL) have been the subject of much recent attention. Such materials are likely to find applications in thick compressively loaded structures such as the keel area of commercial aircraft fuselages. The effects of resin content and its interlaminar and intralaminar distribution on mechanical properties were investigated with test and analysis of two carbon-epoxy systems. The RIL was found to reduce the in situ strengthening effect for matrix cracking in laminates. Mode 2 fracture toughness was found to increase with increasing RIL thickness over the range investigated, and Mode 1 interlaminar toughness was negligibly affected. Compressive failure strains were found to increase with increasing resin content for specimens having no damage, holes, and impact damage. Analytical tools for predicting matrix cracking of off-axis plies and damage tolerance in compression after impact (CAI) were successfully applied to materials with RIL.

Grande, Dodd H.↗

NASA NTRS1991

Nonlinear optical properties of composite materials

The optical properties of a new class of composite nonlinear materials composed of coated grains, such as cadmium sulfide with a silver coating, are examined. These materials exhibit intrinsic optical bistability and resonantly enhanced conjugate reflectivity. The threshold for intrinsic optical bistability is low enough for practical applications in optical communications and optical computing. Some problems associated with the fabrication of these materials are addressed. Based on preliminary results, switching times are expected to be in the subpicosecond range.

Haus, Joseph W.↗

NASA NTRS1956

Preliminary Investigation of Guy Alloy as a Turbojet-engine Bucket Material for Use at 1650 Degrees F

As-cast buckets of Guy alloy, a cast nickel-base material, were run in a J33-9 turbojet engine for cycles of 15 minutes at rated speed and 5 minutes at idle speed. Stress rupture, impace and engine-performance data indicate that Guy alloy may be considered for bucket use at a temperature of 1650 degrees F. Ductility and impact strength of Guy alloy is limited but appears to be adequate for bucket applications.

Signorelli, R A↗

NASA NTRS1994

The effects of specimen scale on the compression strength of composite materials

This paper presents a number of observations on the effect of specimen scale on the compression response of composite materials. Work on this topic was motivated by observations that thick-walled, unstiffened carbon reinforced cylinders subjected to hydrostatic pressure were not reaching inplane laminate stress levels at failure expected from coupon level properties, while similar cylinders reinforced with fiberglass were. Results from a study on coupon strength of (0/0/90) laminates, reinforced with AS4 carbon fiber and S2 glass fiber, are presented and show that compression strength is not a function of material or specimen thickness for materials that have the same laminate quality (autoclave cured quality). Actual laminate compression strength was observed to decrease with increasing thickness, but this is attributed to fixture restraint effects on coupon response. The hypothesis drawn from the coupon level results is further supported by results from a compression test on a thick carbon reinforced coupon in a fixture with reduced influence on specimen response and from a hydrostatic test on an unstiffened carbon reinforced cylinder subjected to hydrostatic pressure with end closures designed to minimize their effect on cylinder response.

Camponeschi, Eugene Thomas, Jr.↗

NASA NTRS1992

Advanced composites structural concepts and materials technologies for primary aircraft structures: Structural response and failure analysis

Non-linear analysis methods were adapted and incorporated in a finite element based DIAL code. These methods are necessary to evaluate the global response of a stiffened structure under combined in-plane and out-of-plane loading. These methods include the Arc Length method and target point analysis procedure. A new interface material model was implemented that can model elastic-plastic behavior of the bond adhesive. Direct application of this method is in skin/stiffener interface failure assessment. Addition of the AML (angle minus longitudinal or load) failure procedure and Hasin's failure criteria provides added capability in the failure predictions. Interactive Stiffened Panel Analysis modules were developed as interactive pre-and post-processors. Each module provides the means of performing self-initiated finite elements based analysis of primary structures such as a flat or curved stiffened panel; a corrugated flat sandwich panel; and a curved geodesic fuselage panel. This module brings finite element analysis into the design of composite structures without the requirement for the user to know much about the techniques and procedures needed to actually perform a finite element analysis from scratch. An interactive finite element code was developed to predict bolted joint strength considering material and geometrical non-linearity. The developed method conducts an ultimate strength failure analysis using a set of material degradation models.

Dorris, William J.↗