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NASA NTRS2006

Foreign Object Damage in a Gas-Turbine Grade Silicon Nitride by Spherical Projectiles of Various Materials

Assessments of foreign object damage (FOD) of a commercial, gas-turbine grade, in situ toughened silicon nitride ceramic (AS800, Honeywell Ceramics Components) were made using four different projectile materials at ambient temperature. AS800 flexure target specimens rigidly supported were impacted at their centers in a velocity range from 50 to 450 m/s by spherical projectiles with a diameter of 1.59 mm. Four different projectile materials were used including hardened steel, annealed steel, silicon nitride ceramic, and brass. Post-impact strength of each target specimen impacted was determined as a function of impact velocity to appraise the severity of local impact damage. For a given impact velocity, the degree of strength degradation was greatest for ceramic balls, least for brass balls, and intermediate for annealed and hardened steel balls. For steel balls, hardened projectiles yielded more significant impact damage than annealed counterparts. The most important material parameter affecting FOD was identified as hardness of projectiles. Impact load as a function of impact velocity was quasi-statically estimated based on both impact and static indentation associated data.

Choi, Sung R.↗

NASA NTRS2010

FOD Prevention at NASA-Marshall Space Flight Center

NASA-MSFC directive MID 5340.1 requires FOD prevention for all flight hardware projects, and requires all support organizations to comply. MSFC-STD-3598 implements a standard approach for FOD prevention, tailored from NAS 412. Three levels of FOD Sensitive Area are identified, adopting existing practices at other NASA facilities. Additional emphasis is given to prevention of impact damage and mitigation of facility FOD sources, especially leaks and spills. Impact Damage Susceptible (IDS) items are identified as FOD-sensitive as well as hardware vulnerable to entrapment of small items.

Lowrey, Nikki M.↗

NASA NTRS1989

Impact behavior of a SiC fiber-reinforced reaction bonded Si3N4 composite

Impact tests were performed on a series of ceramic plate specimens. Monolithic (unreinforced) and composite specimens with various fiber layups were tested to determine the effect that the fiber reinforcement has on impact damage initiation and dynamic response of the ceramic materials. Results show that a porous surface layer of Si3N4 on the composite specimens can enhance the energy absorbing capability of the composite specimens. The addition of SiC fiber reinforcement to the RBSN matrix material is also shown to significantly change the mode of failure and reduce the extent of damage due to impact.

Grady, J.↗

NASA NTRS2007

Damage Tolerance of Composites

Fracture control requirements have been developed to address damage tolerance of composites for manned space flight hardware. The requirements provide the framework for critical and noncritical hardware assessment and testing. The need for damage threat assessments, impact damage protection plans, and nondestructive evaluation are also addressed. Hardware intended to be damage tolerant have extensive coupon, sub-element, and full-scale testing requirements in-line with the Building Block Approach concept from the MIL-HDBK-17, Department of Defense Composite Materials Handbook.

Hodge, Andy↗

NASA NTRS2013

Damage Detection Response Characteristics of Open Circuit Resonant (SansEC) Sensors

The capability to assess the current or future state of the health of an aircraft to improve safety, availability, and reliability while reducing maintenance costs has been a continuous goal for decades. Many companies, commercial entities, and academic institutions have become interested in Integrated Vehicle Health Management (IVHM) and a growing effort of research into "smart" vehicle sensing systems has emerged. Methods to detect damage to aircraft materials and structures have historically relied on visual inspection during pre-flight or post-flight operations by flight and ground crews. More quantitative non-destructive investigations with various instruments and sensors have traditionally been performed when the aircraft is out of operational service during major scheduled maintenance. Through the use of reliable sensors coupled with data monitoring, data mining, and data analysis techniques, the health state of a vehicle can be detected in-situ. NASA Langley Research Center (LaRC) is developing a composite aircraft skin damage detection method and system based on open circuit SansEC (Sans Electric Connection) sensor technology. Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage structures, empennage structures, control surfaces and aircraft skins. SansEC sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect various types of damage in composite materials. The source cause of the in-service damage (lightning strike, impact damage, material fatigue, etc.) to the aircraft composite is not relevant. The sensor will detect damage independent of the cause. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. The unique electrical signatures (amplitude, frequency, bandwidth, and phase) are used for damage detection and diagnosis. An operational system and method would incorporate a SansEC sensor array on select areas of the aircraft exterior surfaces to form a "Smart skin" sensing surface. In this paper a new method and system for aircraft in-situ damage detection and diagnosis is presented. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. NASA LaRC has demonstrated with individual sensors that SansEC sensors can be effectively used for in-situ composite damage detection of delamination, voids, fractures, and rips. Keywords: Damage Detection, Composites, Integrated Vehicle Health Monitoring (IVHM), Aviation Safety, SansEC Sensors

Dudley, Kenneth L.↗

NASA NTRS2020

Repair of Sandwich Structure in Support of the Payload Adapter Fitting (PAF) Part II: Severe Damage Repair

As part of a program examining a Payload Adaptor Fitting (PAF) for NASA’s Space Launch System (SLS), a repair study of impact damage and misdrilled holes in composite sandwich structure was undertaken.1 In that study, it was shown that small holes and barely visible impact damage (BVID) could be repaired and all the measured undamaged in-plane compression strength recovered without removing the damaged material using a simple patch repair. It was noted that for more severe damage, either larger patches or removal of damage (or both) may be necessary to regain all of the measured undamaged compression strength. This Technical Memorandum (TM) presents the results of an experimental investigation into repair of more severely damaged sandwich structure than what was studied in reference 1.

Nettles, A. T.↗

NASA NTRS1994

Foreign body impact event damage formation in composite structures

This report discusses a methodology that can be used to assess the effect of foreign body impacts on composite structural integrity. The described effort focuses on modeling the effect of a central impact on a 5 3/4 inch filament wound test article. The discussion will commence with details of the material modeling that was used to establish the input properties for the analytical model. This discussion is followed by an overview of the impact assessment methodology. The progress on this effort to date is reviewed along with a discussion of tasks that have yet to be completed.

Bucinell, Ronald B.↗

NASA NTRS2006

Shearography NDE of NASA COPV

1. 21 Composite Over-wrapped Pressure Vessels (COPV) consisting of Kevlar Space Shuttle Fleet Leaders and Graphite COPV were inspected at NASA WSTF, NM from Sept. 12 through Sept 16. 2. The inspection technique was Pressurization Shearography, tests designed to image composite material damage, degradation or design flaws leading to stress concentrations in the axial or hoop strain load path. 3. The defect types detected consisted of the following: a) Intentional impact damage with known energy. b) Un-intentional impact damage. c) Manufacturing defects. 4. COPV design features leading to strain concentrations detected include: a) Strain concentrations at bosses due to fiber closure pattern. b) Strain concentrations in body of COPV due to fiber wrap pattern. c) Strain concentrations at equator due to liner weld/fiber lay-up.

Newman, John W.↗

NASA NTRS1999

Stress Analysis and Permeability Testing of Cryogenic Composite Feed Line

For the next generation Single-Stage-To-Orbit (SSTO) Reusable Launch Vehicle (RLV), the use of advanced composite materials is highly desirable and critical to the success of the mission. NASA Marshall Space Flight Center (MSFC) has been working with the aerospace industry for many years to develop and demonstrate the cryogenic composite propellant tanks and feed lines technologies. A 50.8-mm diameter composite feed line for the Clipper Graham (DCY.A) was developed and tested. The purpose of the program is to demonstrate the LH2 permeability, composite to composite and metal joints, as well as composite flange interface of the composite feed line. Stress analysis and permeability testing have been performed on this article. Recently, a larger composite feed line design is being investigated and developed at MSFC for potential use in future RLV. The diameter of the feed line is 203 mm and the overall length is approximately 2.2 meters. This one piece unlined feed line consists of three straight tubular sections joined by two 90 degree elbows. The material chosen is IM7/977-3 prepreg fabric. The lay-up pattern is [0/90, plus or minus 45]s and is built up to 18 plies to the flanges at both ends. A preliminary stress analysis has been conducted to identify potential critical stresses and to develop the finite element analysis (FEA) capability of composite feed lines. As expected, the critical stresses occurred at the rims of some flange holes and the onset of the tapered tubular sections. Further analysis is required to determine the loads, flange deflection, vibration, and combined maximum loads. Two permeability-testing apparatuses were also designed for both flat panel specimens and curved feed line sections after impact damage. A larger permeant gas exposed area is required to accurately determine the effect of impact damage on the permeability of the feed line materials. The flat panel tester was fabricated and assembled. Three test coupons were made of graphite/epoxy plain weave prepreg and unidirectional prepreg. The flow rate was calculated by measuring the change of manometer fluid height per unit time. The permeability of the coupons is then calculated according to Darcy's Law. The pressure increase due to the head rise in the manometer was not considered for the initial estimation. The result of the unidirectional composite coupon agreed with that obtained from the DC-XA feed line testing of a similar material. Further improvement on the design may be required to improve the accuracy and efficiency of permeability testing.

Chu, Tsuchin Philip↗

NASA NTRS1991

Impact response of composite materials

Composite materials composed of carbon fibers and resin matrices offer great promise in reducing the weight of aerospace structures. However they remain extremely vulnerable to out of plane impact loads, which lead to severe losses in strength and stiffness. The results of an experimental program, undertaken to investigate the low velocity impact damage tolerance of composite materials is presented. The objectives were to identify key neat resin/composite properties that lead to enhancement of composite impact damage tolerance and to find a small scale test that predicts compression after impact properties of panels. Five materials were selected for evaluation. These systems represented different classes of material behavior such as brittle epoxy, modified epoxies, and amorphous and semicrystalling thermoplastics. The influence of fiber properties on the impact performance was also studied in one material, i.e., in polyether ether ketone (PEEK). Several 24 and 48 ply quasi-isotropic and 24 ply orthotropic laminates were examined using an instrumented drop weight impactor. Correlations with post impact compression behavior were made.

Tiwari, S. N.↗

NASA NTRS2011

FOD Prevention at NASA-Marshall Space Flight Center

NASA now requires all flight hardware projects to develop and implement a Foreign Object Damage (FOD) Prevention Program. With the increasing use of composite and bonded structures, NASA now also requires an Impact Damage Protection Plan for these items. In 2009, Marshall Space Flight Center released an interim directive that required all Center organizations to comply with FOD protocols established by on-site Projects, to include prevention of impact damage. The MSFC Technical Standards Control Board authorized the development of a new MSFC technical standard for FOD Prevention.

Lowrey, Nikki M.↗

NASA NTRS1983

Observation of damage growth in compressively loaded laminates

Graphite/epoxy laminates have a definite advantage with respect to the strength-to-weight relation over many standard engineering materials used in aerospace applications. However, this advantage is somewhat reduced by the sensitivity of these laminates to operational hazards, which include a low-velocity impact by foreign objects. Investigations conducted by Chai (1982) and Knauss et al. (1980) have been concerned with the growth of impact damage in compressively loaded laminates, and the visualization of such an impact damage. The present study represents a condensation of parts of these investigations, taking into account a determination of the damage-growth mechanism via real-time recording of the impact event. The material considered, a T300/5208 graphite/epoxy laminate, is typical of the configuration proposed for future heavily loaded primary structures. It has stiffness properties similar to those of the wing skins in existing transport aircraft.

Knauss, W. G.↗

NASA NTRSDate not supplied

The Application of Artificial Intelligence Deep Learning to Visually Identify Micrometeoroid and Orbital Debris Impacts

Recent advances in Artificial Intelligence (AI) are changing the World. Novel approaches to training AI systems have led to dramatic reductions in the amount of time required. Training an AI system could take years and teams of people using traditional methods, but with the advancements of Deep Learning (DL) models this training can now be accomplished by an individual in a matter of minutes. The development of “fast AI” libraries has delivered AI to essentially everyone. Democratization of AI power has inspired many to revisit past problems that will benefit from DL approaches. For example, the application of AI has improved detection of breast cancer by 20% compared to traditional detection methods. Computer vision and machine learning are being used to identify soil deficiencies and provide planting recommendations to farmers. Success stories like these and many others have provided inspiration to see if AI can help improve one of our needed capabilities – that of visually identifying micrometeoroid and orbital debris (MMOD) impact damage to spacecraft from images of the spacecraft exterior. The need to visually locate and characterize spacecraft MMOD impact damage has been present since the early days of space travel. This is often done by either having a crew member take photographs of the spacecraft through a window using a hand-held camera or ground personnel directing externally-mounted cameras. The photographs are then transmitted back to Earth for visual analysis. This method of MMOD damage inspection works well and has been used on various spacecraft including the Space Shuttle and the International Space Station (ISS). One of the issues with the current method that we believe AI could improve is the speed and possibly the accuracy in identifying MMOD impacts. Note that detecting MMOD impacts in images can be very difficult. The visual appearance of an MMOD impact can change dramatically with lighting conditions, size of impact, depth of penetration, material types, surface waviness, fabric coverings, camera & lens, distance to surface, spacecraft orientation, analyst experience, and many other factors. Currently, this takes a team of highly-experienced specialists in both the fields of Image Analysis and MMOD impacts. This paper documents our initial research in training an AI DL model using the fast-AI library to identify actual and simulated MMOD impacts and perforations into exposed flat surfaces. While we recognize that this initial goal seems modest, it must be noted that what we have done would have taken teams of individuals and years of training just ten years ago. Our long-term goal is to add complexity and use-cases to the DL model being trained to expand the capabilities of this model so that it can be used to identify MMOD impacts on all types of spacecraft surfaces.

Cameron M Collins↗

NASA NTRS2008

High Performance COPVs for In-Space Storage of High Pressure Cryogenic Fuels

Polymeric composite overwrapped pressure vessels (COPVs) provide an attractive material system to support developing commercial launch business and alternate fuel ventures. However to be able to design with these materials, the mechanical behavior of the materials must be understood with regards to processing, performance, damage tolerance, and environment. For the storage of cryogenic propellants, it is important to evaluate the materials performance and impact damage resistance at cryogenic temperatures in order to minimize weight and to ensure safety and reliability. As part of this study, material tests of candidate fiber and resin systems were used as the basis for the selection of the material combinations for evaluation in a COPV at cryogenic conditions. This comprehensive approach has also been expanded to address issues with impact damage tolerance and material degradation due to environmental factors. KEY WORDS: Cryogenic testing, evaluation and applications for pressure vessels, COPVs, tanks, or storage vessels.

Schneider, Judy↗

NASA NTRS2001

Evaluation of the Structural Response and Failure of a Full-Scale Stitched Graphite-Epoxy Wing

Analytical and experimental results for an all-composite full-scale wing box are presented. The wing box is representative of a section of a 220-passenger commercial transport aircraft wing box and was designed and constructed by The Boeing Company as part of the NASA Advanced Subsonics Technology (AST) program. The semi-span wing was fabricated from a graphite-epoxy material system with cover panels and spars held together using Kevlar stitches through the thickness. No mechanical fasteners were used to hold the stiffeners to the skin of the cover panels. Tests were conducted with and without low-speed impact damage, discrete source damage and repairs. Upbending, down-bending and brake roll loading conditions were applied. The structure with nonvisible impact damage carried 97% of Design Ultimate Load prior to failure through a lower cover panel access hole. Finite element and experimental results agree for the global response of the structure.

Jegley, Dawn C.↗

NASA NTRS2014

Detailed Post-Soft Impact Progressive Damage Assessment for Hybrid Structure Jet Engines

Currently, certification of engine designs for resistance to bird strike is reliant on physical tests. Predictive modeling of engine structural damage has mostly been limited to evaluation of individual forward section components, such as fan blades within a fixed frame of reference, to direct impact with a bird. Such models must be extended to include interactions among engine components under operating conditions to evaluate the full extent of engine damage. This paper presents the results of a study aim to develop a methodology for evaluating bird strike damage in advanced propulsion systems incorporating hybrid composite/metal structures. The initial degradation and failure of individual fan blades struck by a bird were investigated. Subsequent damage to other fan blades and engine components due to resultant violent fan assembly vibrations and fragmentation was further evaluated. Various modeling parameters for the bird and engine components were investigated to determine guidelines for accurately capturing initial damage and progressive failure of engine components. Then, a novel hybrid structure modeling approach was investigated and incorporated into the crashworthiness methodology. Such a tool is invaluable to the process of design, development, and certification of future advanced propulsion systems.

bird strike↗

NASA NTRS2013

Fabrication and Testing of Durable Redundant and Fluted-Core Joints for Composite Sandwich Structures

The development of durable bonded joint technology for assembling composite structures is an essential component of future space technologies. While NASA is working toward providing an entirely new capability for human space exploration beyond low Earth orbit, the objective of this project is to design, fabricate, analyze, and test a NASA patented durable redundant joint (DRJ) and a NASA/Boeing co-designed fluted-core joint (FCJ). The potential applications include a wide range of sandwich structures for NASA's future launch vehicles. Three types of joints were studied -- splice joint (SJ, as baseline), DRJ, and FCJ. Tests included tension, after-impact tension, and compression. Teflon strips were used at the joint area to increase failure strength by shifting stress concentration to a less sensitive area. Test results were compared to those of pristine coupons fabricated utilizing the same methods. Tensile test results indicated that the DRJ design was stiffer, stronger, and more impact resistant than other designs. The drawbacks of the DRJ design were extra mass and complex fabrication processes. The FCJ was lighter than the DRJ but less impact resistant. With barely visible but detectable impact damages, all three joints showed no sign of tensile strength reduction. No compression test was conducted on any impact-damaged sample due to limited scope and resource. Failure modes and damage propagation were also studied to support progressive damage modeling of the SJ and the DRJ.

Lin, Shih-Yung↗

NASA NTRS2008

Material Damage from Impacts of Lunar Soil Particles Ejected by the Rocket Exhaust of Landing Spacecraft

This paper details the experimentation of lunar stimulant sandblasting. This was done to understand the damage that landing spacecraft on the moon will have to a permanent lunar outpost. The sandblasting was done with JSC-1A onto glass coupons. Correlations between the velocity and the damage done to the glass were not found. Reasons for this and future analyses are discussed.

Wittbrodt, Audelia C.↗