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At least 235 records · Page 13
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NASA NTRS2021

Application of a Developmental Composite Material Model to Predict the Crush Response of Two Energy Absorbers

In 2012, a consortium was formed with the goal of creating a new composite material model capable of predicting the wide range of properties, accumulated damage behavior, and the many different types of failure in composites under impact loading. The material model was developed for execution in the commercially available nonlinear, explicit transient dynamic finite element code, LS-DYNA®. This material model incorporates three sub-models: deformation, damage, and failure. In addition, the model accounts for strain rate and temperature effects and relies heavily on the input of tabulated material response data. The model is designated *MAT_COMPOSITE_TABULATED_PLASTICITY_DAMAGE, or *MAT_213. Initially, *MAT_213 was developed for use with solid elements only; however, a thin shell element formulation for *MAT_213 has been adapted recently. The objective of this project was to find a suitable modeling example to investigate the capabilities and performance of *MAT_213. In 2012, two composite energy absorbers were designed and evaluated at NASA Langley Research Center through multi-level testing and simulation. The first was a conical-shaped energy absorber, designated the conusoid, which consisted of four layers of hybrid carbon-Kevlar® plain-weave fabric oriented at [+45°/-45°/-45°/+45°] with respect to the vertical direction. The second was a sinusoidal-shaped energy absorber, designated the sinusoid, which consisted of hybrid carbon-Kevlar® plain-weave fabric face sheets, two layers for each face sheet oriented at ±45° with respect to the vertical direction, and a closed-cell ELFOAM® P200 polyisocyanurate foam core. Finite element models were developed of the energy absorbers and simulations were performed using LS-DYNA®. In this paper, the development of a *MAT_213 model of a hybrid carbon-Kevlar® plain-weave fabric is presented. Next, comparisons with material characterization tests are presented. Then, test-analysis results are documented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading using the *MAT_213 material model. Since a prior *MAT_58, or *MAT_LAMINATED_COMPOSITE_FABRIC material model was used in previous simulations of the energy absorbers, comparisons are made between *MAT_58 and *MAT_213 model predictions with test data. Finally, the paper includes a comprehensive list of “lessons learned,” in which a series of parametric studies are documented that were performed to investigate specific issues related to the material model. These “lessons learned” are included in hopes that they may help future *MAT_213 users.

crashworthiness, LS-DYNA transient dynamic simulat↗
NASA NTRS1989

An evaluation of the interfacial bond properties between carbon phenolic and glass phenolic composites

The effects of moisture and surface finish on the mechanical and physical properties of the interfacial bond between the carbon/phenolic (C/P) and glass/phenolic (G/P) composite materials are presented. Four flat panel laminates were fabricated using the C/P and G/P materials. Of the four laminates, one panel was fabricated in which the C/P and G/P materials were cured simultaneously. It was identified as the cocure. The remaining laminates were processed with an initial simultaneous cure of the three C/P billets. Two surface finishes, one on each half, were applied to the top surface. Prior to the application and cure of the G/P material to the machined surface of the three C/P panels, each was subjected to the specific environmental conditioning. Types of conditioning included: (1) nominal fabrication environment, (2) a prescribed drying cycle, and (3) a total immersion in water at 160 F. Physical property tests were performed on specimens removed from the C/P materials of each laminate for determination of the specific gravity, residual volatiles and and resin content. Comparisons of results with shuttle solid rocket motor (SRM) nozzle material specifications verified that the materials used in fabricating the laminates met acceptance criteria and were representative of SRM nozzle materials. Mechanical property tests were performed at room temperature on specimens removed from the G/P, the C/P and the interface between the two materials for each laminate. The double-notched shear strength test was used to determine the ultimate interlaminar shear strength. Results indicate no appreciable difference in the C/P material of the four laminates with the exception of the cocure laminate, where 20 percent reduction in the strength was observed. The most significant effect and the ultimate strength was significantly reduced in the wet material. No appreciable variation was noted between the surface finishes in the wet laminate.

Jordan, Kelvin↗
NASA NTRS1991

Analysis of the optimal laminated target made up of discrete set of materials

A new class of problems was analyzed to estimate an optimal structure of laminated targets fabricated from the specified set of homogeneous materials. An approximate description of the perforation process is based on the model of radial hole extension. The problem is solved by using the needle-type variation technique. The desired optimization conditions and quantitative/qualitative estimations of optimal targets were obtained and are discussed using specific examples.

Aptukov, Valery N.↗
NASA NTRS2015

Microstructural Influence on Deformation and Fatigue Life of Composites Using the Generalized Method of Cells

A fully coupled deformation and damage approach to modeling the response of composite materials and composite laminates is presented. It is based on the semi-­‐analytical generalized method of cells (GMC) micromechanics model as well as its higher fidelity counterpart, HFGMC, both of which provide closed-form constitutive equations for composite materials as well as the micro scale stress and strain fields in the composite phases. The provided constitutive equations allow GMC and HFGMC to function within a higher scale structural analysis (e.g., finite element analysis or lamination theory) to represent a composite material point, while the availability of the micro fields allow the incorporation of lower scale sub­‐models to represent local phenomena in the fiber and matrix. Further, GMC's formulation performs averaging when applying certain governing equations such that some degree of microscale field accuracy is surrendered in favor of extreme computational efficiency, rendering the method quite attractive as the centerpiece in a integrated computational material engineering (ICME) structural analysis; whereas HFGMC retains this microscale field accuracy, but at the price of significantly slower computational speed. Herein, the sensitivity of deformation and the fatigue life of graphite/epoxy PMC composites, with both ordered and disordered microstructures, has been investigated using this coupled deformation and damage micromechanics based approach. The local effects of fiber breakage and fatigue damage are included as sub‐models that operate on the microscale for the individual composite phases. For analysis of laminates, classical lamination theory is employed as the global or structural scale model, while GMC/HFGMC is embedded to operate on the microscale to simulate the behavior of the composite material within each laminate layer. A key outcome of this study is the statistical influence of microstructure and micromechanics idealization (GMC or HFGMC) on the overall accuracy of unidirectional and laminated composite deformation and fatigue response.

Microscale Models↗
NASA NTRS1991

Mechanical property characterization and impact resistance of selected graphite/PEEK composite materials

To use graphite/PEEK material on highly curved surfaces requires that the material be drapable and easily conformable to the surface. The mechanical property characterization and impact resistance results are presented for laminates made from two types of graphite/PEEK materials that will conform to a curved surface. These laminates were made from two different material forms. These forms are: (1) a fabric where each yarn is a co-mingled Celion G30-500 3K graphite fiber and PEEK fiber; and (2) an interleaved material of Celion G30-500 3K graphite fiber interleaved with PEEK film. The experimental results from the fabric laminates are compared with results for laminates made from AS4/PEEK unidirectional tape. The results indicate that the tension and compression moduli for quasi-isotropic and orthotropic laminates made from fabric materials are at least 98 pct. of the modulus of equivalent laminates made from tape materials. The strength of fabric material laminates is at least 80 pct. of laminates made from tape material. The evaluation of the fabric material for shear stiffness indicates that a tape material laminate could be replaced by a fabric material laminate and still maintain 89 pct. of the shear stiffness of the tape material laminate.

Baker, Donald J.↗
NASA NTRS1994

Mechanical property characterization and impact resistance of selected graphite/PEEK composite materials

To use graphite polyetheretherketone (PEEK) material on highly curved surfaces requires that the material be drapable and easily conformable to the surface. This paper presents the mechanical property characterization and impact resistance results for laminates made from two types of graphite/PEEK materials that will conform to a curved surface. These laminates were made from two different material forms. These forms are: (1) a fabric where each yarn is a co-mingled Celion G30-500 3K graphite fiber and PEEK thermoplastic fiber; and (2) an interleaved material of Celion G30-500 3K graphite fabric interleaved with PEEK thermoplastic film. The experimental results from the fabric laminates are compared with results for laminates made from AS4/PEEK unidirectional tape. The results indicate that the tension and compression moduli for quasi-isotropic and orthotropic laminates made from fabric materials are at least 79 percent of the modulus of equivalent laminates made from tape material. The strength of fabric material laminates is at least 80 percent of laminates made from tape material. The evaluation of fabric material for shear stiffness indicates that a tape material laminate could be replaced by a fabric material laminate and still maintain 89 percent of the shear stiffness of the tape material laminate. The notched quasi-isotropic compression panel failure strength is 42 to 46 percent of the unnotched quasi-isotropic laminate strength. Damage area after impact with 20 ft-lbs of impact energy is larger for the co-mingled panels than for the interleaved panels. The inerleaved panels have less damage than panels made from tape material. Residual compression strength of quasi-isotropic panels after impact of 20 ft-lbs of energy varies between 33 percent of the undamaged quasi-isotropic material strength for the tape material and 38 percent of the undamaged quasi-isotropic material strength for the co-mingled fabric material.

Baker, Donald J.↗
NASA NTRS2013

Elevated Temperature, Notched Compression Performance of Out of Autoclave Processed Composites

Curved honeycomb sandwich panels composed of carbon fiber reinforced toughened-epoxy polymer facesheets are being evaluated for potential use as payload fairing components on the NASA heavy-lift space launch system (HL-SLS). These proposed composite sandwich panels provide the most efficient aerospace launch structures, and offer mass and thermal advantages when compared with existing metallic payload fairing structures. NASA and industry are investigating recently developed carbon fiber epoxy prepreg systems which can be fabricated using out-of autoclave (OOA) processes. Specifically, OOA processes using vacuum pressure in an oven and thereby significantly reducing the cost associated with manufacturing large (up to 10 m diameter) composite structures when compared with autoclave. One of these OOA composite material systems, CYCOM(R) 5320-1, was selected for manufacture of a 1/16th scale barrel portion of the payload fairing; such that, the system could be compared with the well-characterized prepreg system, CYCOM(R) 977-3, typically processed in an autoclave. Notched compression coupons for each material were obtained from the minimum-gauge flat laminate [60/-60/0]S witness panels produced in this manufacturing study. The coupons were also conditioned to an effective moisture equilibrium point and tested according to ASTM D6484M-09 at temperatures ranging from 25 C up to 177 C. The results of this elevated temperature mechanical characterization study demonstrate that, for thin coupons, the OHC strength of the OOA laminate was equivalent to the flight certified autoclave processed composite laminates; the limitations on the elevated temperature range are hot-wet conditions up to 163 C and are only within the margins of testing error. At 25 C, both the wet and dry OOA material coupons demonstrated greater OHC failure strengths than the autoclave processed material laminates. These results indicate a substantial improvement in OOA material development and processing since previous studies have consistently reported OOA material strengths on par or below those of autoclave processed composite laminates.

Grimsley, Brian W.↗
NASA NTRS1974

Investigation of Kevlar fabric based materials for use with inflatable structures

Design, manufacture and testing of laminated and coated composite materials incorporating a structural matrix of Kevlar are reported in detail. The practicality of using Kevlar in aerostat materials is demonstrated and data are provided on practical weaves, lamination and coating particulars, rigidity, strength, weight, elastic coefficients, abrasion resistance, crease effects, peel strength, blocking tendencies, helium permeability, and fabrication techniques. Properties of the Kevlar based materials are compared with conventional, Dacron reinforced counterparts. A comprehensive test and qualification program is discussed and quantitative biaxial tensile and shear test data are provided. The investigation shows that single ply laminates of Kevlar and plastic films offer significant strength to weight improvements, are less permeable than two ply coated materials, but have a lower flex life.

Niccum, R. J.↗
NASA NTRS1975

Fatigue of notched fiber composite laminates. Part 1: Analytical model

A description is given of a semi-empirical, deterministic analysis for prediction and correlation of fatigue crack growth, residual strength, and fatigue lifetime for fiber composite laminates containing notches (holes). The failure model used for the analysis is based upon composite heterogeneous behavior and experimentally observed failure modes under both static and fatigue loading. The analysis is consistent with the wearout philosophy. Axial cracking and transverse cracking failure modes are treated together in the analysis. Cracking off-axis is handled by making a modification to the axial cracking analysis. The analysis predicts notched laminate failure from unidirectional material fatique properties using constant strain laminate analysis techniques. For multidirectional laminates, it is necessary to know lamina fatique behavior under axial normal stress, transverse normal stress and axial shear stress. Examples of the analysis method are given.

Mclaughlin, P. V., Jr.↗
NASA NTRS1983

Process Yields Strong, Void-Free Laminates

Need for lightweight materials as structural components for future space transportation systems stimulated development of systematic method for manufacturing a polyimide/graphite composite. Laminates manufactured by process are void-free, exhibit excellent thermo-oxidative stability up to 315 degrees C (600 degrees F) and are 40 percent lighter than aluminum. Process is precise, repeatable, and ideally suited for researchers and small-lot producers of composite materials.

Bryant, L. E.↗
NASA NTRS1977

Investigation of Kevlar fabric-based materials for use with inflatable structures

Design, manufacture and testing of laminated and coated composite materials incorporating a structural matrix of Kevlar are reported. The practicality of using Kevlar in aerostat materials is demonstrated, and data are provided on practical weaves, lamination and coating particulars, rigidity, strength, weight, elastic coefficients, abrasion resistance, crease effects, peel strength, blocking tendencies, helium permeability, and fabrication techniques. Properties of the Kevlar-based materials are compared with conventional Dacron-reinforced counterparts. A comprehensive test and qualification program is discussed, and considerable quantitative biaxial tensile and shear test data are provided.

Niccum, R. J.↗
NASA NTRS1985

Fracture and crack growth in orthotropic laminates

A mathematical model based on the classical shear-lag assumptions is used to study the residual strength and fracture behavior of composite laminates with symmetrically placed buffer strips. The laminate is loaded by a uniform remote longitudinal tensile strain and has initial damage in the form of a transverse crack in the parent laminate between buffer strips. The crack growth behavior as a function of material properties, number of buffer-strip plies, spacing, width of buffer strips, longitudinal matrix splitting, and debonding at the interface is studied. Buffer-strip laminates are shown to arrest fracture and increase the residual strengths significantly over those of one material laminates, with S-glass being a more effective buffer strip material than Kevlar in increasing the damage tolerance of graphite/epoxy panels. For a typical graphite/epoxy laminate with S-glass buffer-strips, the residual strength is about 2.4 times the residual strength of an all graphite/epoxy panel with the same crack length. Approximately 50% of this increase is due to the S-glass/epoxy buffer-strips, 40% due to longitudinal splitting of the buffer strip interface and 10% due to bonding.

Goree, James G.↗
NASA NTRS1984

Hygrothermal influence on delamination behavior of graphite/epoxy laminates

The hygrothermal effect on the fracture behavior of graphite-epoxy laminates was investigated to develop a methodology for damage tolerance predictions in advanced composite materials. Several T300/934 laminates were tested using a number of specimen configurations to evaluate the effects of temperature and humidity on delamination fracture toughness under mode 1 and mode 2 loading. It is indicated that moisture has a slightly beneficial influence on fracture toughness or critical strain energy release rate during mode 1 delamination, but has a slightly deleterious effect on mode 2 delamination and mode 1 transverse cracking. The failed specimens are examined by SEM and topographical differences due to fracture modes are identified. It is concluded that the effect of moisture on fracture topography can not be distinguished.

Garg, A.↗
NASA NTRS1985

Hygrothermal influence on delamination behavior of graphite/epoxy laminates

The hygrothermal effect on the fracture behavior of graphite-epoxy laminates was investigated to develop a methodology for damage tolerance predictions in advanced composite materials. Several T300/934 laminates were tested using a number of specimen configurations to evaluate the effects of temperature and humidity on delamination fracture toughness under mode 1 and mode 2 loading. It is indicated that moisture has a slightly beneficial influence on fracture toughness or critical strain energy release rate during mode 1 delamination, but has a slightly deleterious effect on mode 2 delamination, and mode 1 transverse cracking. The failed specimens are examined by SEM and topographical differences due to fracture modes are identified. It is concluded that the effect of moisture on fracture topography can not be distinguished.

Garg, A.↗
NASA NTRS1998

Ma'adim Vallis Estuarine Delta in Elysium Basin and Its Relevance as a Landing Site for Exobiology Exploration on Mars

The debouche of Ma'adim Vallis in the Elysium Basin generated a transitional transported sediment structure, which planimetric shape is controlled by the enclosing topography of a deep reentrant gulf of the Basin into the highland. We defined it as an estuarine delta. The location and the importance of this estuarine delta is supported by the theoretical model of graded profile constructed for Ma'adim Vallis, and by two approaches: (i) the reconstruction of Ma'adim Vallis downstream course from Gusev to Elysium Basin, and (ii) the survey of the sediment deposit in the alleged estuary. The longitudinal graded profile of Ma'adim Vallis finds its base-level in the Elysium Basin, at a about 1000 m elevation, which is in agreement with the observed Basin shoreline. This model is supported by observational evidence of flow between the northern rim of Gusev crater, and the Elysium Basin shoreline. This downstream course of Ma'adim Vallis can be divided into three hydrogeologic regions. into three hydrogeologic regions. (a) The first region is a flooded plain (Zephiria Mensae), consisting in chaotic terrain formed by highland rocks, and disintegrated lava of the western flank of Apollinaris. Morphologic indicators of the flood process are: (1) the sediment deposit over the Gusev crater northern rim that reflects the overspilling of the crater-lake water through a 40-km wide gap provided by an ancient impact crater, (2) the tear-drop shaped feature on the northeastern flank of Apollinaris Patera, and (3) the chaotic terrain that suggest the emergence of ground water generated by the seepage of the crater lake through high-permeable broken rampart material. This underground water circulation sustained by the hydrostatic pressure of the crater-lake has likely generated a hydrothermal system in the volcanic environment of Apollinaris Patera. The stratigraphy of the flooded area is identified as Hesperian age, with occurrences of Noachian hilly individual features, and as Amazonian flooded plain and chaotic material, (b) The second region is located on the western flank of Apollinaris Patera. It is surrounded by relics of deep valleys that suggest a former downstream course of Ma'adim Vallis. The geologic setting of this region (Lucus Planum) is interpreted to be an Amazonian formation composed by the middle and lower members of the Medusae Formation., c) The third region corresponds to the convergence of the west and east branches of Ma'adirn Vallis into a deep re-entrant wide gulf that penetrates about 100 km into the highland. This topographic depression is delineated by the 1000 in elevation contour. This gulf has formed an estuarine configuration centered at 3S/190W within the Elysium Basin. This configuration has favored the formation of a estuarine sedimentary delta, because of topographically controlled lateral migration. This estuarine structure is strongly dominated by the incoming supply of Ma'adim Vallis fluvial sediment extracted from Zephiria Mensae and Lucus Planum. The obtuse-angle geometry of the estuary increases the sedimentation rate, which is higher than in the course of the channel. The sediment deposition process is governed by the estuarine water circulation. The inflowing loaded fluvial water enters the estuary as a bottom current, and mixes with the relatively less-loaded water of the receiving basin. When they mixed. the inflowing fluvial material, and the landward basin circulating water generate an accumulation of highly-diversified estuarine deposit stratification. This accumulation of material is mostly centered in the transitional zone of the delta. The sediment trapping efficiency of the estuary is function of the energy balance between the inflowing fluvial water, and the ingoing basin current. The submergence of the delta by the rising of the water-level increases the estuary water-depth, and consequently the sediment entrapment is favored. The locus of sediment accumulation moves landward in the zone of inflowing fluvial water. This results in the rising of the channel base-level, thus in the increase of the length of the longitudinal graded-profile. The sediment deposit facies of the zone A shows a generally smooth surface. The longitudinal deposit is bordered by alluvial terraces that reflect the variations of the channel level. The waning of the Elysium Basin caused the erosion of the Basin estuarine zone by small channels, this episode being characterized by dissected tear-drop shaped mesa-like morphologies in the delta. Our estuarine delta model predicts a lithostratigraphic depositional sequence associated with the water submergence and the transgression of Elysium Basin. The thickness of the estuarine sediment corresponds to the Elysium Basin levels changes relatively to the bed floor of the estuary, The depositional sequence of Ma'adim Vallis are described: (1) a pro-current filled region (A), where fluvial are longitudinally accumulated by the inflowing water, (2) inverse current from Elysium Basin (B), where fluvial and lacustrine sediments are accumulated, and (3) zone of current equilibrium (C), where the sediments are distributed as a shoreline at the boundary of the estuarine delta. The estuary sedimentology dynamics collects and keeps the record of the geologic unit material crossed by Ma'adim Vallis, and those of the lakebed deposit of Elysium Basin. The predicted mixed stratigraphic sequence from fluvial and lacustrine sediment makes this site an exceptional environment to concentrate potential multi-origin biologic records. We envision four possible strategies to explore this sedimentologic record: (1) longitudinal surface and subsurface traverses in region A to investigate outcrop levees, (2) exploration of the mesa walls in region B, (3) deep drilling hole lodging of the sequential deposits in the zones A and B, and (4) surface and subsurface exploration of the shoreline delta. The expected results for each of these strategies are: (1) in the deepest layers of region A are predicted frequent and abundant coarse material, sandy lenses lamination grading downward from sand to cobbles. Volcanic debris from the Noachian crustal Plateau unit material, hydrothermal altered rocks, carbonates, Hesperian and possibly Amazonian volcanic material, from Apollinaris Patera, altered rocks and carbonates from Zephiria Mensae are expected. As a favorable environment for inception of life, possible biological records are expected in transported rock, (2) At the surface, and subsurface (<=100 m), large deposits sandy to silted material from Elysium paleolake basin mixed with fine-grained sediments from Ma'adim Vallis are expected mostly in the upstream part of region B, (3) on the shoreline of the estuarine delta, abundant fine material from Elysium paleolake basin (evaporites, carbonates), mostly Amazonian in age are expected. The Ma'adini estuary is a favorable landing site for all the above mentioned science aspects, and .for its location. The site lies near the equator, which is favorable for the rover solar power supply, and at 1000m elevation, which is a favorable configuration for the descent system braking. Another advantage is the extent of the area of high scientific interest (33,000 sq km), which provides a good ellipse, and potential long study traverses.

Grin, E. A.↗
NASA NTRS2019

Evaluation of Ultem 1000, 1010, and 9085 for Radome Applications at 24.5 GHz

The UAS in the NAS project Flight Test 6 (FT6) campaign scheduled for FY19Q3 will evaluate the proficiency of a Honeywell DAPA-Lite Radar installed on a Tiger Shark unmanned vehicle to detect the presence of air traffic operating in its vicinity. A 3D printed radome will be manufactured for the front of the Tiger Shark to enclose the radar during FT6 operations. The DAPA-Lite radar operates in the 24.5 GHz frequency band. Material properties of 3D printer filaments are widely available for the mechanical and thermal properties, but limited knowledge exists on the electrical properties for radome applications and no data was found to correspond at the 24.5 Ghz frequency band. To minimize project risk associated with the radome performance, transmissivity and reflectivity measurements were conducted on two candidate 3D printed dielectric material filaments (Ultem 1010 Natural and Ultem 9085 Black) and two thicknesses of a solid laminate (Ultem 1000) material. The 3D printed Ultem coupons were tested shortly after being printed and again 8 months later to examine ageing effects of the open cell structure. This paper presents the transmissivity and reflectivity measurement results collected on the Ultem coupons and concludes the 3D printed 1010 Natural coupon is a suitable candidate filament for radome applications at 24.5 GHz. The design of the structure’s open cell matrix has a significant impact on the material’s surface reflectivity.

Szatkowski, George N.↗
NASA NTRS1976

Investigation of thermal fatigue in fiber composite materials

Graphite-epoxy laminates were thermally cycled to determine the effects of thermal cycles on tensile properties and thermal expansion coefficients of the laminates. Three 12-ply laminate configurations were subjected to up to 5,000 thermal cycles. The cumulative effect of the thermal cycles was determined by destructive inspection (electron micrographs and tensile tests) of samples after progressively larger numbers of cycles. After thermal cycling, the materials' tensile strengths, moduli, and thermal expansion coefficients were significantly lower than for the materials as fabricated. Most of the degradation of properties occurred after only a few cycles. The property degradation was attributed primarily to the progressive development of matrix cracks whose locations depended upon the layup orientation of the laminate.

Fahmy, A. A.↗