Mechanical behavior of carbon-fiber reinforced- epoxy composites.
Carbon fiber reinforcing and epoxy resin composites mechanical properties for NOL ring, belt, cylinder and tube-column specimens
Davis, J. G., Jr.↗
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Near Zone: Basic scattering code user's manual with space station applications
The Electromagnetic Code - Basic Scattering Code, Version 3, is a user oriented computer code to analyze near and far zone patterns of antennas in the presence of scattering structures, to provide coupling between antennas in a complex environment, and to determine radiation hazard calculations at UHF and above. The analysis is based on uniform asymptotic techniques formulated in terms of the Uniform Geometrical Theory of Diffraction (UTD). Complicated structures can be simulated by arbitrarily oriented flat plates and an infinite ground plane that can be perfectly conducting or dielectric. Also, perfectly conducting finite elliptic cylinder, elliptic cone frustum sections, and finite composite ellipsoids can be used to model the superstructure of a ship, the body of a truck, and airplane, a satellite, etc. This manual gives special consideration to space station modeling applications. This is a user manual designed to give an overall view of the operation of the computer code, to instruct a user in how to model structures, and to show the validity of the code by comparing various computed results against measured and alternative calculations such as method of moments whenever available.
Marhefka, R. J.↗
Studies of fiber-matrix adhesion on compression strength
A study was initiated on the effect of the matrix polymer and the fiber matrix bond strength of carbon fiber polymer matrix composites. The work includes tests with micro-composites, single ply composites, laminates, and multi-axial loaded cylinders. The results obtained thus far indicate that weak fiber-matrix adhesion dramatically reduces 0 degree compression strength. Evidence is also presented that the flaws in the carbon fiber that govern compression strength differ from those that determine fiber tensile strength. Examination of post-failure damage in the single ply tests indicates kink banding at the crack tip.
Bascom, Willard D.↗
The isothermal fatigue behavior of a unidirectional SiC/Ti composite and the Ti alloy matrix
The high temperature fatigue behavior of a metal matrix composite (MMC) consisting of Ti-15V-3Cr-3Al-3Sn(Ti-15-3) matrix reinforced by 33 volume percent of continuous unidirectional SiC fibers was experimentally and analytically evaluated. Isothermal MMC fatigue tests with constant amplitude loading parallel to the fiber direction were performed at 300 and 550 C. Comparative fatigue tests of the Ti-15-3 matrix alloy were also performed. Composite fatigue behavior and the in situ stress state of the fiber and matrix were analyzed with a micromechanical model, the Concentric Cylinder Model (CCM). The cyclic stress-strain response of the composite was stable at 300 C. However, an increase in cyclic mean strain foreshortened MMC fatigue life at high strain ranges at 550 C. Fatigue tests of the matrix alloy and CCM analyses indicated this response was associated with stress relaxation of the matrix in the composite and subsequent load shedding to the fibers.
Gayda, John↗
The isothermal fatigue behavior of a unidirectional SiC/Ti composite and the Ti alloy matrix
The high temperature fatigue behavior of a metal matrix composite (MMC) consisting of Ti-15V-3Cr-3Al-3Sn (Ti-15-3) matrix reinforced by 33 vol percent of continuous unidirectional SiC fibers was experimentally and analytically evaluated. Isothermal MMC fatigue tests with constant amplitude loading parallel to the fiber direction were performed at 300 and 550 C. Comparative fatigue tests of the Ti-15-3 matrix alloy were also conducted. Composite fatigue behavior and the in-situ stress state of the fiber and matrix were analyzed with a micromechanical model, the Concentric Cylinder Model (CCM). The cyclic stress-strain response of the composite was stable at 300 C. However, an increase in cyclic mean strain foreshortened MMC fatigue life at high strain ranges at 550 C. Fatigue tests of the matrix alloy and CCM analyses indicated this response was associated with stress relaxation of the matrix in the composite.
Gayda, John, Jr.↗
Cracking of a layered medium on an elastic foundation under thermal shock
The cladded pressure vessel under thermal shock conditions which is simulated by using two simpler models was studied. The first model (Model 1) assumes that, if the crack size is very small compared to the vessel thickness, the problem can be treated as a semi-infinite elastic medium bonded to a very thin layer of different material. However, if the crack size is of the same order as the vessel thickness, the curvature effects may not be negligible. In this case it is assumed that the relatively thin walled hollow cylinder with cladding can be treated as a composite beam on an elastic foundation (Model 2). In both models, the effect of surface cooling rate is studied by assuming the temperature boundary condition to be a ramp function. The calculated results include the transient temperature, thermal stresses in the uncracked medium and stress intensity factors which are presented as a function of time, and the duration of cooling ramp. The stress intensity factors are also presented as a function of the size and the location of the crack. The problem is solved for two bonded materials of different thermal and mechanical properties. The mathematical formulation results in two singular integral equations which are solved numerically. The results are given for two material pairs, namely an austenitic steel layer welded on a ferritic steel substrate, and a ceramic coating on ferritic steel. In the case of the yielded clad, the stress intensity factors for a crack under the clad are determined by using a plastic strip model and are compared with elastic clad results.
Rizk, Abd El-Fattah A.↗
Properties Of Carbon/Carbon and Carbon/Phenolic Composites
Report presents data on physical properties of carbon-fiber-reinforced carbon-matrix and phenolic-matrix composite materials. Based on tests conducted on panels, cylinders, blocks, and formed parts. Data used by designers to analyze thermal-response and stress levels and develop structural systems ensuring high reliability at minimum weight.
Mathis, John R.↗
Effects of fiber and interfacial layer architectures on the thermoplastic response of metal matrix composites
Examined here is the effect of fiber and interfacial layer morphologies on thermal fields in metal matrix composites (MMCs). A micromechanics model based on an arbitrarily layered concentric cylinder configuration is used to calculate thermal stress fields in MMCs subjected to spatially uniform temperature changes. The fiber is modelled as a layered material with isotropic or orthotropic elastic layers, whereas the surrounding matrix, including interfacial layers, is treated as a strain-hardening, elastoplastic, von Mises solid with temperature-dependent parameters. The solution to the boundary-value problem of an arbitrarily layered concentric cylinder under the prescribed thermal loading is obtained using the local/global stiffness matrix formulation originally developed for stress analysis of multilayered elastic media. Examples are provided that illustrate how the morphology of the SCS6 silicon carbide fiber and the use of multiple compliant layers at the fiber/matrix interface affect the evolution of residual stresses in SiC/Ti composites during fabrication cool-down.
Pindera, Marek-Jerzy↗
Ultrasonic evaluation of mechanical properties of thick, multilayered, filament wound composites
A preliminary investigation is conducted to define capabilities and limitations of ultrasonic and acousto-ultrasonic measurements related to mechanical properties of filament wound graphite/epoxy composite structures. The structures studied are segments of filament wound cylinders formed of multiple layers of hoop and helical windings. The segments consist of 24 to 35 layers and range from 3.02 to 3.34 cm in wall thickness. The resultant structures are anisotropic, heterogeneous, porous, and highly attenuating to ultrasonic frequencies greater than 1 MHz. The segments represent structures to be used for space shuttle booster cases. Ultrasonic velocity and acousto-ultrasonic stress wave factor measurement approaches are discussed. Correlations among velocity, density, and porosity, and between the acousto-ultrasonic stress wave factor and interlaminar shear strength are presented.
Kautz, H. E.↗
Ultrasonic evaluation of mechanical properties of thick, multilayered, filament-wound composites
A preliminary investigation is conducted to define capabilities and limitations of ultrasonic and acousto-ultrasonic measurements related to mechanical properties of filament wound graphite/epoxy composite structures. The structures studied are segments of filament wound cylinders formed of multiple layers of hoop and helical windings. The segments consist of 24 to 35 layers and range from 3.02 to 3.34 cm in wall thickness. The resultant structures are anisotropic, heterogeneous, porous, and highly attenuating to ultrasonic frequencies greater than 1 MHz. The segments represent structures to be used for Space Shuttle booster cases.Ultrasonic velocity and acousto-ultrasonic stress wave factor measurement approaches are discussed. Correlations among velocity, density, and porosity, and between the acousto-ultrasonic stress wave factor and interlaminar shear strength are presented.
Kautz, H. E.↗
Micromechanics of composites with shape memory alloy fibers in uniform thermal fields
Analytical procedures are developed for a composite system consisting of shape memory alloy fibers within an elastic matrix subject to uniform temperature fluctuations. Micromechanics for the calculation of the equivalent properties of the composite are presented by extending the multi-cell model to incorporate shape memory alloy fibers. A three phase concentric cylinder model is developed for the analysis of local stresses which includes the fiber, the matrix, and the surrounding homogenized composite. The solution addresses the complexities induced by the nonlinear dependence of the in-situ martensite fraction of the fibers to the local stresses and temperature, and the local stresses developed from interactions between the fibers and matrix during the martensitic and reverse phase transformations. Results are presented for a nitinol/epoxy composite. The applications illustrate the response of the composite in isothermal longitudinal loading and unloading, and in temperature induced actuation. The local stresses developed in the composite under various stages of the martensitic and reverse phase transformation are also shown.
Birman, Victor↗
Lightning induced currents in aircraft wiring using low level injection techniques
Various techniques were studied to predict the transient current induced into aircraft wiring bundles as a result of an aircraft lightning strike. A series of aircraft measurements were carried out together with a theoretical analysis using computer modeling. These tests were applied to various aircraft and also to specially constructed cylinders installed within coaxial return conductor systems. Low level swept frequency CW (carrier waves), low level transient and high level transient injection tests were applied to the aircraft and cylinders. Measurements were made to determine the transfer function between the aircraft drive current and the resulting skin currents and currents induced on the internal wiring. The full threat lightning induced transient currents were extrapolated from the low level data using Fourier transform techniques. The aircraft and cylinders used were constructed from both metallic and CFC (carbon fiber composite) materials. The results show the pulse stretching phenomenon which occurs for CFC materials due to the diffusion of the lightning current through carbon fiber materials. Transmission Line Matrix modeling techniques were used to compare theoretical and measured currents.
Stevens, E. G.↗
Investigation of Carbon-Polymer Structures with Embedded Fiber-Optic Bragg Gratings
Several Bragg-grating sensors fabricated within the same optical fiber are buried within multiple-ply carbon-epoxy planar and cylindrical structures. Effect of different orientation of fiber-sensors with respect to carbon fibers in the composite structure is investigated. This is done for both fabric and uni-tape material samples. Response of planar structures to axial and transverse strain up to 1 millistrain is investigated with distributed Bragg-grating sensors. Material properties like Young's Modulus and Poisson ratio is measured. A comparison is made between response measured by sensors in different ply-layers and those bonded on the surface. The results from buried fiber- sensors do not completely agree with surface bonded conventional strain gauges. A plausible explanation is given for observed differences. The planar structures are subjected to impacts with energies up to 10 ft-lb. Effect of this impact on the material stiffness is also investigated with buried fiber-optic Bragg sensors. The strain response of such optical sensors is also measured for cylindrical carbon-epoxy composite structures. The sensors are buried within the walls of the cylinder as well as surface bonded in both the axial as well as hoop directions. The response of these fiber-optic sensors is investigated by pressurizing the cylinder up to its burst pressure of around 1500 psi. This is done at both room temperature as well as cryogenic temperatures. The recorded response is compared with that from a conventional strain gauge.
Grant, Joseph↗
A finite element-boundary integral method for cavities in a circular cylinder
Conformal antenna arrays offer many cost and weight advantages over conventional antenna systems. However, due to a lack of rigorous mathematical models for conformal antenna arrays, antenna designers resort to measurement and planar antenna concepts for designing non-planar conformal antennas. Recently, we have found the finite element-boundary integral method to be very successful in modeling large planar arrays of arbitrary composition in a metallic plane. We extend this formulation to conformal arrays on large metallic cylinders. In this report, we develop the mathematical formulation. In particular, we discuss the shape functions, the resulting finite elements and the boundary integral equations, and the solution of the conformal finite element-boundary integral system. Some validation results are presented and we further show how this formulation can be applied with minimal computational and memory resources.
Kempel, Leo C.↗
ICAN Computer Code Adapted for Building Materials
The NASA Lewis Research Center has been involved in developing composite micromechanics and macromechanics theories over the last three decades. These activities have resulted in several composite mechanics theories and structural analysis codes whose applications range from material behavior design and analysis to structural component response. One of these computer codes, the Integrated Composite Analyzer (ICAN), is designed primarily to address issues related to designing polymer matrix composites and predicting their properties - including hygral, thermal, and mechanical load effects. Recently, under a cost-sharing cooperative agreement with a Fortune 500 corporation, Master Builders Inc., ICAN was adapted to analyze building materials. The high costs and technical difficulties involved with the fabrication of continuous-fiber-reinforced composites sometimes limit their use. Particulate-reinforced composites can be thought of as a viable alternative. They are as easily processed to near-net shape as monolithic materials, yet have the improved stiffness, strength, and fracture toughness that is characteristic of continuous-fiber-reinforced composites. For example, particlereinforced metal-matrix composites show great potential for a variety of automotive applications, such as disk brake rotors, connecting rods, cylinder liners, and other hightemperature applications. Building materials, such as concrete, can be thought of as one of the oldest materials in this category of multiphase, particle-reinforced materials. The adaptation of ICAN to analyze particle-reinforced composite materials involved the development of new micromechanics-based theories. A derivative of the ICAN code, ICAN/PART, was developed and delivered to Master Builders Inc. as a part of the cooperative activity.
Murthy, Pappu L. N.↗
Processing and Testing of Thermoplastic Composite Cylindrical Shells Fabricated by Automated Fiber Placement
Two 61-cm-diameter eight-ply quasi-isotropic IM7/PEEK cylindrical shells were fabricated by automated fiber placement the NASA Langley Research Center using only infrared radiant heat to preheat the substrate and incoming composite uni-tape. The shells were characterized by ultrasonic c-scans for overall consolidation quality, and by optical microscopy and acid digestion for void content. Compression tests were also performed. Although the material used in the study was of generally poor quality due to numerous splits and dry fiber regions, the process was able to achieve a net reduction in void content in the as-placed component. Microscopy of the composite shells revealed well-consolidated, void-free interfaces. The two cylinders were then tested in uni-axial compression in a 1334 kN-capacity hydraulic test machine until buckling occurred. A geometrically nonlinear finite element analysis was conducted, and the differences between the predicted and measured values were 18.0 and 25.8%, respectively. Inclusion of measured imperfections of the cylinder into the analysis is expected to reduce these differences.
Hulcher, Anthony Bruce↗
Goals and Progress for Mil Handbook 17, Vol. 5 on Ceramic Matrix Composites: Testing and Characterization
The initial edition of the Mil Handbook 17, Vol. 5 on ceramic matrix composites (CMCs) was recently published. Part C of this CMC volume describes procedures for characterization of the thermal, physical, and mechanical properties of CMCs and subsequent data analysis procedures. As is the case for entire CMC volume, this chapter is a "work in progress" with sections on recommended test plans and matrices, data reduction, and test methods. This presentation will describe the current status in development of this section of the CMC volume and will highlight examples of critical issues that will be addressed in this volume. CMC systems are a different class of material than metals or polymer matrix composite with different mechanical response and failure modes, design rules, test methods, and characterization techniques. The CMC test protocols need to include guidance on how to generate enough reliable data in order to estimate, with reasonable confidence, the lower bounds of performance properties, such as strength and life. Strength data sets on two material systems, C/SiC and Nicalon/SiNC, and a creep rupture data set on C/SiC, will be presented to highlight this issue. The structural properties of CMC parts can sometimes be significantly different than those obtained from flat panels because of changes in fiber architecture often required to make shapes and spatial and lot-to-lot variations in processing conditions. To illustrate an example, the hoop tensile properties of SiC/SiC cylinders will be compared to properties obtained from flat panels fabricated from the same composites. These CMC testing-design issues are being defined and documented in the Mil Handbook 17 CMC volume.
Verrilli, Michael J.↗
Weight comparisons of optimized stiffened, unstiffened, and sandwich cylindrical shells made from composite or aluminum materials
This work presents optimum designs for unstiffened, hat stringer-stiffened and honeycomb sandwich cylinders under axial compression. Optimization results for graphite-epoxy cylinders show about a 50 percent weight savings over corresponding optimized aluminum cylinders for a wide loading range. The inclusion of minimum gage considerations results in a significant weight penalty, especially for a lightly loaded cylinder. Effects of employing a smeared stiffener buckling theory in the optimization program are investigated through comparison of results obtained from a more accurate branched shell buckling computer code. It was found that the stiffener cross-sectional deformations, which are usually ignored in smeared stiffener theory, result in about a 30 percent lower buckling load for the graphite-epoxy hat stiffened cylinder.
Agarwal, B. L.↗