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DOE OSTI2025

Compression Response of Silicone-Based Composites with Integrated Multifunctional Fillers

Polydimethylsiloxane (PDMS) is known for its exceptional mechanical properties, chemical stability, and flexibility. Recent advancements have focused on developing functional PDMS composites by integrating various functional fillers, including polymers, ceramics, and metals, for advanced applications such as electronics, medical devices, and aerospace. Consequently, there is a growing need to investigate PDMS composites to achieve higher filler loadings offering enhanced mechanical performance. This study addresses this need by utilizing the high molecular weight (MW) PDMS resin we have developed, offering its high elongation capacity of up to >6500%. We incorporated boron (B), hollow glass microballoons (HGMs), and tungsten-coated hollow glass microballoons (WHGMs) into the developed high MW PDMS. The resulting composites demonstrated excellent elastic properties and significant compression resilience (35–80%) and elastic modulus (1.28–10.15 MPa) at high filler loadings (~60 vol.%). Specifically, B/PDMS composites achieved up to 67.6 vol.% of B, HGM/PDMS composites held up to 68.6 vol.% of HGM, and WHGM/PDMS composites incorporated up to 54.0 vol.% of WHGM. These findings highlight the potential of high MW PDMS for developing high-performance PDMS composites suitable for advanced applications such as aerospace, automotive, and medical devices.

36 MATERIALS SCIENCE↗

NASA NTRS1984

Temperature dependence of elastic and strength properties of T300/5208 graphite-epoxy

Experimental results are presented for the elastic and strength properties of T300/5208 graphite-epoxy at room temperature, 116K (-250 F), and 394K (+250 F). Results are presented for unidirectional 0, 90, and 45 degree laminates, and + or - 30, + or - 45, and + or - 60 degree angle-ply laminates. The stress-strain behavior of the 0 and 90 degree laminates is essentially linear for all three temperatures and that the stress-strain behavior of all other laminates is linear at 116K. A second-order curve provides the best fit for the temperature is linear at 116K. A second-order curve provides the best fit for the temperature dependence of the elastic modulus of all laminates and for the principal shear modulus. Poisson's ratio appears to vary linearly with temperature. all moduli decrease with increasing temperature except for E (sub 1) which exhibits a small increase. The strength temperature dependence is also quadratic for all laminates except the 0 degree - laminate which exhibits linear temperature dependence. In many cases the temperature dependence of properties is nearly linear.

Milkovich, S. M.↗

NASA NTRS1995

Modeling and characterization of through-the-thickness properties of 3D woven composites

The through-the-thickness properties of three-dimensionally (3D) woven carbon/epoxy composites have been studied. The investigation aimed at the evaluation and development of test methodologies for the property characterization in the thickness direction, and the establishment of fiber architectures were studied: layer-to-layer Angle Interlock, through-the-thickness Orthogonal woven preform with surface pile was also designed and manufactured for the fabrication of tensile test coupons with integrated grips. All the preforms were infiltrated by the resin transfer molding technique. The microstructures of the composites were characterized along the warp and fill (weft) directions to determine the degree of yarn undulations, yarn cross-sectional shapes, and microstructural dimensions. These parameters were correlated to the fiber architecture. Specimens were designed and tested for the direct measurement of the through-the-thickness tensile, compressive and shear properties of the composites. Design optimization was conducted through the analysis of the stress fields within the specimen coupled with experimental verification. The experimentally-derived elastic properties in the thickness direction compared well with analytical predictions obtained from a volume averaging model.

Hartranft, Dru↗

NASA NTRSDate not supplied

Multi-Scale Analysis of Effective Mechanical Properties of Porous 3D Woven Composite Materials

This work aims to compute and analyze the mechanical properties of 3D woven composite materials that share the same yarn structure but differ in their matrix porosity and yarn's fiber volume fraction. Assuming linear elastic behavior, NASA's PuMA software was used to characterize the different composites from their constituents' data, averaging their elastic properties in three main directions to obtain their effective orthotropic mechanical properties. This was performed in three steps: firstly, the porous matrix phase was analyzed at the micro-scale; then, these results were used, along with the mechanical properties of the fibers, to model the yarns at the meso-scale; finally, results from the constituents were homogenized and used to model the mechanical behavior of the unit cell at the macro-scale. The 3D woven composite materials selected for this study are made of a mixture of phenolic resin with porosity values between 0 and 0.6, and infiltrated carbon fiber yarns with fiber volume fractions between 0.5 and 0.8. Results from this study show the effect of different matrix porosities and fiber volume fractions on the macro-scale mechanical properties, and were validated through theoretical and semi-empirical expressions found in the literature.

3D woven materials↗

NASA NTRS1972

Lattice model calculation of elastic and thermodynamic properties at high pressure and temperature

The elastic constants and the entire frequency spectrum were calculated up to high pressure for the alkali halides in the NaCl lattice, based on an assumed functional form of the inter-atomic potential. The quasiharmonic approximation is used to calculate the vibrational contribution to the pressure and the elastic constants at arbitrary temperature. By explicitly accounting for the effect of thermal and zero point motion, the adjustable parameters in the potential are determined to a high degree of accuracy from the elastic constants and their pressure derivatives measured at zero pressure. The calculated Gruneisen parameter, the elastic constants and their pressure derivatives are in good agreement with experimental results up to about 600 K. The model predicts that for some alkali halides the Grunesen parameter may decrease monotonically with pressure, while for others it may increase with pressure, after an initial decrease.

Demarest, H. H., Jr.↗

DOE OSTI2025

Rippled metamaterials with scale-dependent tailorable elasticity

Thermally induced ripples are intrinsic features of nanometer-thick films, atomically thin materials, and cell membranes, significantly affecting their elastic properties. Despite decades of theoretical studies on the mechanics of suspended thermalized sheets, controversy still exists over the impact of these ripples, with conflicting predictions about whether elasticity is scale-dependent or scale-independent. Experimental progress has been hindered so far by the inability to have a platform capable of fully isolating and characterizing the effects of ripples. This knowledge gap limits the fundamental understanding of thin materials and their practical applications. Here, we show that thermal-like static ripples shape thin films into a class of metamaterials with scale-dependent, customizable elasticity. Utilizing a scalable semiconductor manufacturing process, we engineered nanometer-thick films with precisely controlled frozen random ripples, resembling snapshots of thermally fluctuating membranes. Resonant frequency measurements of rippled cantilevers reveal that random ripples effectively renormalize and enhance the average bending rigidity and sample-to-sample variations in a scale-dependent manner, consistent with recent theoretical estimations. The predictive power of the theoretical model, combined with the scalability of the fabrication process, was further exploited to create kirigami architectures with tailored bending rigidity and mechanical metamaterials with delayed buckling instability.

Applied Physical Sciences↗

NASA NTRS1991

Ultrasonic evaluation of oxidation and reduction effects on the elastic behavior and global microstructure of YBa2Cu3O7-x

Ultrasonic velocity measurement techniques were used to evaluate the effects of oxidation and reduction on the elastic properties, global microstructure and oxygen content of the YBa2Cu3O(7-x) ceramic superconductor for samples ranging from 70 to 90 pct. of theoretical density. Bulk density, velocity, and elastic modulus generally increased with increasing oxygen content upon oxidation, and this behavior was reversible. Velocity image patterns were similar after oxidation and reduction treatments for a 90 pct. dense sample, although the velocity value at any given point on the sample was changed following the treatments. The unchanging pattern correlated with destructive measurements showing that the spatial pore distribution (fraction and size) was not measurably altered after the treatments. Changes in superconducting behavior, crystal structure, and grain structure were observed consistent with changes in oxygen content.

Roth, Don J.↗

NASA NTRS1992

Ultrasonic evaluation of oxygen content, modulus, and microstructure changes in YBa2Cu3O(7-x) occurring during oxidation and reduction

Ultrasonic velocity measurement techniques were used to evaluate the effects of oxidation and reduction on the elastic properties, global microstructure and oxygen content of the YBa2Cu3O(7-x) ceramic superconductor for samples ranging from 70 to 90 pct of theoretical density. Bulk density, velocity, and elastic modulus generally increased with increasing oxygen content upon oxidation, and this behavior was reversible. Velocity image patterns were similar after oxidation and reduction treatments for a 90 pct. dense sample, although the velocity value at any given point on the sample was changed following the treatments. The unchanging pattern correlated with destructive measurements showing that the spatial pore distribution (fraction and size) was not measurably altered after the treatments. Changes in superconducting behavior, crystal structure, and grain structure were observed consistent with changes in oxygen content.

Roth, Don J.↗

NASA NTRS2013

Elastic-Plastic J-Integral Solutions or Surface Cracks in Tension Using an Interpolation Methodology

No closed form solutions exist for the elastic-plastic J-integral for surface cracks due to the nonlinear, three-dimensional nature of the problem. Traditionally, each surface crack must be analyzed with a unique and time-consuming nonlinear finite element analysis. To overcome this shortcoming, the authors have developed and analyzed an array of 600 3D nonlinear finite element models for surface cracks in flat plates under tension loading. The solution space covers a wide range of crack shapes and depths (shape: 0.2 less than or equal to a/c less than or equal to 1, depth: 0.2 less than or equal to a/B less than or equal to 0.8) and material flow properties (elastic modulus-to-yield ratio: 100 less than or equal to E/ys less than or equal to 1,000, and hardening: 3 less than or equal to n less than or equal to 20). The authors have developed a methodology for interpolating between the goemetric and material property variables that allows the user to reliably evaluate the full elastic-plastic J-integral and force versus crack mouth opening displacement solution; thus, a solution can be obtained very rapidly by users without elastic-plastic fracture mechanics modeling experience. Complete solutions for the 600 models and 25 additional benchmark models are provided in tabular format.

Allen, P. A.↗

NASA NTRS2013

Elastic-Plastic J-Integral Solutions or Surface Cracks in Tension Using an Interpolation Methodology. Appendix C -- Finite Element Models Solution Database File, Appendix D -- Benchmark Finite Element Models Solution Database File

Allen, Phillip A.↗

NASA NTRS1973

Mechanical property determination of high conductivity metals and alloys

Pertinent mechanical properties of three high conductivity metals and alloys; namely, vacuum hot pressed grade S-200E beryllium, OFHC copper and beryllium-copper alloy no. 10 were determined. These materials were selected based on their possible use in rocket thrust chamber and nozzle hardware. They were procured in a form and condition similar to that which might be ordered for actual hardware fabrication. The mechanical properties measured include (1) tension and compression stress strain curves at constant strain rate (2) tensile and compressive creep, (3) tensile and compressive stress-relaxation behavior and (4) elastic properties. Tests were conducted over the temperature range of from 75 F to 1600 F. The resulting data is presented in both graphical and tabular form.

Harrod, D. L.↗

NASA NTRS1995

Development and computer implementation of design/analysis techniques for multilayered composite structures. Probabilistic fiber composite micromechanics

Probabilistic composite micromechanics methods are developed that simulate expected uncertainties in unidirectional fiber composite properties. These methods are in the form of computational procedures using Monte Carlo simulation. The variables in which uncertainties are accounted for include constituent and void volume ratios, constituent elastic properties and strengths, and fiber misalignment. A graphite/epoxy unidirectional composite (ply) is studied to demonstrate fiber composite material property variations induced by random changes expected at the material micro level. Regression results are presented to show the relative correlation between predictor and response variables in the study. These computational procedures make possible a formal description of anticipated random processes at the intraply level, and the related effects of these on composite properties.

Stock, Thomas A.↗

NASA NTRS1996

Probabilistic Fiber Composite Micromechanics

Probabilistic composite micromechanics methods are developed that simulate expected uncertainties in unidirectional fiber composite properties. These methods are in the form of computational procedures using Monte Carlo simulation. The variables in which uncertainties are accounted for include constituent and void volume ratios, constituent elastic properties and strengths, and fiber misalignment. A graphite/epoxy unidirectional composite (ply) is studied to demonstrate fiber composite material property variations induced by random changes expected at the material micro level. Regression results are presented to show the relative correlation between predictor and response variables in the study. These computational procedures make possible a formal description of anticipated random processes at the intra-ply level, and the related effects of these on composite properties.

Stock, Thomas A.↗

NASA NTRS1992

Nonlinear Elastic Effects on the Energy Flux Deviation of Ultrasonic Waves in GR/EP Composites

In isotropic materials, the direction of the energy flux (energy per unit time per unit area) of an ultrasonic plane wave is always along the same direction as the normal to the wave front. In anisotropic materials, however, this is true only along symmetry directions. Along other directions, the energy flux of the wave deviates from the intended direction of propagation. This phenomenon is known as energy flux deviation and is illustrated. The direction of the energy flux is dependent on the elastic coefficients of the material. This effect has been demonstrated in many anisotropic crystalline materials. In transparent quartz crystals, Schlieren photographs have been obtained which allow visualization of the ultrasonic waves and the energy flux deviation. The energy flux deviation in graphite/epoxy (gr/ep) composite materials can be quite large because of their high anisotropy. The flux deviation angle has been calculated for unidirectional gr/ep composites as a function of both fiber orientation and fiber volume content. Experimental measurements have also been made in unidirectional composites. It has been further demonstrated that changes in composite materials which alter the elastic properties such as moisture absorption by the matrix or fiber degradation, can be detected nondestructively by measurements of the energy flux shift. In this research, the effects of nonlinear elasticity on energy flux deviation in unidirectional gr/ep composites were studied. Because of elastic nonlinearity, the angle of the energy flux deviation was shown to be a function of applied stress. This shift in flux deviation was modeled using acoustoelastic theory and the previously measured second and third order elastic stiffness coefficients for T300/5208 gr/ep. Two conditions of applied uniaxial stress were considered. In the first case, the direction of applied uniaxial stress was along the fiber axis (x3) while in the second case it was perpendicular to the fiber axis along the laminate stacking direction (x1).

Prosser, William H.↗

NASA NTRS1971

Design properties of randomly reinforced fiber/resin composites

The pseudoisotropic laminate analogy is used in conjunction with fiber composite micro and macromechanics to predict the thermal and mechanical properties of planar randomly reinforced fiber composites (PRRFC). Theoretical results are presented for boron/epoxy, Thornel-50/epoxy, and S-glass/epoxy PRRFC. The results show that the thermal and elastic properties depend on both constituent materials and the fiber volume ratio. The strength depends also on the type of applied stress.

Chamis, C. C.↗

NASA NTRS1972

Design properties of randomly reinforced fiber/resin composites.

The pseudoisotropic laminate analogy is used in conjunction with fiber composite micro and macromechanics to predict the thermal and mechanical properties of planar randomly reinforced fiber composites (PRRFC). Theoretical results are presented for boron/epoxy, Thornel-50/epoxy, and S-glass/epoxy PRRFC. The results show that the thermal and elastic properties depend on both constituent materials and the fiber volume ratio (FVR). The strength depends also on the type of applied stress.

Chamis, C. C.↗

DOE OSTI2025

Mapping the structural–mechanical landscape of amorphous carbon with ReaxFF molecular dynamics

We use ReaxFF molecular dynamics (MD) to investigate the relationship between structural and mechanical properties in bulk and nanostructured amorphous carbon (a-C). The liquid-quench MD method is used to generate isotropic bulk samples with mass densities ranging from 0.96 to 3.29 g/cm3. Structural analysis identifies two types of structures with distinct short- and medium-range order: lower-density sp2-dominated a-C, which is characterized by a bimodal ring-size distribution, and higher-density sp3-dominated tetrahedral amorphous carbon (ta-C), exhibiting a unimodal ring-size distribution. Stress–strain MD simulations and analysis reveal how an atomistic structure impacts elastic properties and post-yield atomic rearrangements. All stretched structures demonstrate elastic isotropy and plasticity driven by a ring-size expansion mechanism reflected in changes in ring statistics. The plastic region is substantially larger in ta-C than in a-C due to the post-yield shift from sp3 to sp2 C dominant bonding. In both a-C and ta-C, ultimate failure occurs when a reactive crack, traversed by long sp chains, forms and propagates predominantly perpendicular to the direction of the applied strain. Oxygen infiltration into the fractured region significantly reduces stress resistance, primarily through the early rupture of long sp chains. MD simulations and analysis are extended to a-C slabs, a-C nanotubes, and partially a-C nanotubes. The latter nanostructure highlights the differences between the elastically isotropic a-C walls, which develop circumferential cracking, and the crystalline walls, which tear along crystallographic directions. These results provide a strong foundation for further computational characterization of a-C materials.

Dernov, A. (ORCID:0009000004220973)↗

NASA NTRS1972

Design properties of randomly reinforced fiber composites

The pseudoisotropic-laminate analogy is used in conjunction with fiber composite micro- and macromechanics to predict the thermal and mechanical properties of planar randomly reinforced fiber composites (PRRFC). Theoretical results are presented for boron/aluminum, boron/epoxy, Thornel-50/epoxy, and S-glass/epoxy PRRFC. The results show that the thermal and elastic properties depend on both constituent materials and the fiber volume ratio. The strength depends also on the type of applied stress. In general, no simple ratio exists between the properties of unidirectional fiber composites and those of PRRFC. The data are presented in convenient graphical form to serve as an aid for design and/or analysis and also for further research in PRRFC. The residual stresses and the impact resistance are also theoretically examined.

Chamis, C. C.↗