Cumulative damage effects of viscoelastic fracture Semiannual progress report
Investigating energy concept of adhesive failure and pressurized disk test for measuring adhesive value of bonded elastomers
Williams, M. L.↗
SEARCH · Search NASA
Results for “Progressive Failure”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Effect of damage on elastically tailored composite laminates
A variationally consistent theory is derived in order to predict the response of anisotropic thin-walled closed sections subjected to axial load, torsion and bending. The theory is valid for arbitrary cross-sections made of laminated composite materials with variable thickness and stiffness. Closed form expressions for the stiffness coefficients are provided as integrals in terms of lay-ups parameters and cross-sectional geometry. A comparison of stiffness coefficients and response with finite element predictions and a closed form solution is performed. The theory is applied to the investigation of the effect of damage on the extension-twist coupling in a thin-walled closed section beam. The damage is simulated as a progressive ply-by-ply failure. Results show that damage can have a significant effect on the extension-twist coupling.
Armanios, Erian↗
Characterization of Damage Accumulation in a C/SiC Composite at Elevated Temperatures
This research is part of a program aimed to evaluate and demonstrate the ability of candidate CMC materials for a variety of applications in reusable launch vehicles. The life and durability of these materials in rocket and engine applications are of major concern and there is a need to develop and validate life prediction methodology. In this study, material characterization and mechanical testing was performed in order to identify the failure modes, degradation mechanisms, and progression of damage in a C/SiC composite at elevated temperatures. The motivation for this work is to provide the relevant damage information that will form the basis for the development of a physically based life prediction methodology.
Telesman, Jack↗
Real Time Detection of Damage During Quasi-Static Loading of a Single Stringer Panel Using Passive Thermography
Real time nondestructive evaluation is required for composites load testing. The early detection and measurement of damage progression is important to understand failure modes. A single stringer panel was subjected to quasi-static loading to induce deformation which can result in the formation of delamination damage between the stiffener flange and skin. Passive thermography was used to detect damage in real time as a function of the applied load. The loading was stopped when damage growth was detected. Of particular interest was the early detection of damage formation which can be challenging, as compared to cyclic fatigue loading. Passive thermography data were acquired and processed in real time and revealed damaged areas due to heating from fiber breakage and delamination formation. The processed thermal imagery was also compared to acoustic emission and ultrasound data.
Zalameda, Joseph N.↗
Detection of Damage During Quasi-Static Loading of a Single Stringer Panel Using Passive Thermography and Acoustic Emission
The purpose of this paper is to describe the methodology of measuring damage onset and growth in a composite structure during quasi-static loading using passive thermography and acoustic emission. The early detection and measurement of damage progression is important to understand failure modes. A single stringer panel was subjected to quasi-static loading to induce deformation which resulted in the formation of damage between the stiffener flange and skin. The loading was stopped when damage growth was detected. Passive thermography and acoustic emission were used to detect damage in real-time as a function of the applied load. Of particular interest are the small transient thermographic signals resulting from damage formation which can be challenging to detect, as compared to the persistent passive thermography indications of cyclic fatigue loading. We describe a custom developed thermal inspection system for detection of composite damage during quasi-static loading. The thermal results are compared to a two-dimensional multi-layered thermal simulation based on the quadrupole method. Acoustic emission is used to further characterize the damage by comparing the acoustic emission events with the thermal imagery. Results are compared to ultrasonic measurements to document the damage through-the-thickness.
Zalameda, Joseph N.↗
Probabilistic structural analysis: Introductory remarks
The development of probabilistic structural analysis methodology consists of the following program elements: (1) composite load spectra models, (2) computational probabilistic structural analysis methods, and (3) probabilistic constitutive relationships. The development of the probabilistic structural analysis methodology is a joint program of NASA Lewis in-house and sponsored research. The objective of this session is to illustrate recent progress on the application of this methodology to determine the reliability of structural components for rocket propulsion systems. The session contains descriptions of and progress reports on the following specific activities: (1) The NESSUS computer code, (2) approximate methods, (3) advanced methods, (4) composite load spectra applications, (5) probabilistic fracture mechanisms, and (6) probability of failure and risk analysis. Collectively, the progress to date demonstrates that the structural durability of hot engine structural components can be effectively evaluated in a formal probabilistic/reliability framework.
Chamis, Christos C.↗
Progressive Fracture of Laminated Fiber-Reinforced Composite Stiffened Plate Under Pressure
S-Glass/epoxy laminated fiber-reinforced composite stiffened plate structure with laminate configuration (0/90)5 was simulated to investigate damage and fracture progression, under uniform pressure. For comparison reasons a simple plate was examined, in addition with the stiffened plate. An integrated computer code was used for the simulation. The damage initiation began with matrix failure in tension, continuous with damage and/or fracture progression as a result of additional matrix failure and fiber fracture and followed by additional interply delamination. Fracture through the thickness began when the damage accumulation was 90%. After that stage, the cracks propagate rapidly and the structures collapse. The collapse load for the simple plate is 21.57 MPa (3120 psi) and for the stiffened plate 25.24 MPa (3660 psi).
Gotsis, Pascalis K.↗
Derivation of Failure Rates and Probability of Failures for the International Space Station Probabilistic Risk Assessment Study
National Aeronautics and Space Administration s (NASA) International Space Station (ISS) Program uses Probabilistic Risk Assessment (PRA) as part of its Continuous Risk Management Process. It is used as a decision and management support tool to not only quantify risk for specific conditions, but more importantly comparing different operational and management options to determine the lowest risk option and provide rationale for management decisions. This paper presents the derivation of the probability distributions used to quantify the failure rates and the probability of failures of the basic events employed in the PRA model of the ISS. The paper will show how a Bayesian approach was used with different sources of data including the actual ISS on orbit failures to enhance the confidence in results of the PRA. As time progresses and more meaningful data is gathered from on orbit failures, an increasingly accurate failure rate probability distribution for the basic events of the ISS PRA model can be obtained. The ISS PRA has been developed by mapping the ISS critical systems such as propulsion, thermal control, or power generation into event sequences diagrams and fault trees. The lowest level of indenture of the fault trees was the orbital replacement units (ORU). The ORU level was chosen consistently with the level of statistically meaningful data that could be obtained from the aerospace industry and from the experts in the field. For example, data was gathered for the solenoid valves present in the propulsion system of the ISS. However valves themselves are composed of parts and the individual failure of these parts was not accounted for in the PRA model. In other words the failure of a spring within a valve was considered a failure of the valve itself.
Vitali, Roberto↗
Quasi-Static and Dynamic Analysis of Composite Panels: Challenges in Engineering-Level Commercial Software
In engineering applications, where analysis time and efficiency are essential, analytical models and commercially available finite element (FE) material models are the two mainstream methods used to analyze composite crush scenarios. A reliable numerical model addressing the crushing response of composite materials requires a nonlinear progressive damage analysis which includes appropriate failure mechanisms such as matrix cracking, fragmentation, delamination, and fiber breakage. One might be able to address all these interacting failure responses through implementation/validation of a user defined material model or by utilization of a commercially available model, the latter being the most efficient engineering approach. In this paper, the quasi-static and dynamic crushing response of composite specimens, consisting of a C-channel and a corrugated geometry manufactured with carbon fiber/epoxy matrix fabric, are modeled using the progressive composite damage model within ABAQUS. The novel part of this work, which has not been previously addressed in the literature, is the utilization of a detailed parametric study to optimize composite damage model parameters for a given quasi-static crush simulation in ABAQUS. C-channel experiments were used to calibrate the model and then refine/optimize a set of material parameters that best fit the experimental results. These identical parameters were then used to simulate the crush response of the corrugated channel specimens, thereby making it a pure prediction and not a double recalibration. Next, the dynamic response of both panels were predicted, further confirming the predictive capability of the developed numerical model. The effect of parameter variation on the crush response is fully documented for future use in engineering applications utilizing this specific ABAQUS damage model.
Paria Naghipour↗
Prediction of Composite Laminate Fracture: Micromechanics and Progressive Fracture
An investigation is described on the prediction of first-ply failure and fracture in selected composite laminates. The laminates are made from glass fibers and graphite fibers in epoxy matrices. Failure envelopes are generated for combined loading of these laminates on the basis of first-ply failure and laminate fracture. The evaluation is performed by a micromechanics-based theory and progressive fracture.
Gotsis, P. K.↗
Prediction of Composite Laminate Fracture: Micromechanics and Progressive Fracture
An investigation is described on the prediction of first-ply failure and fracture in selected composite laminates. The laminates are made from glass fibers and graphite fibers in epoxy matrices. Failure envelopes are generated for combined loading of these laminates on the basis of first-ply failure and laminate fracture. The evaluation is performed by a micromechanics-based theory and progressive fracture.
Gotsis, P. K.↗
Structural system reliability under multiple failure modes
This paper describes a computational method for system reliability estimation of propulsion structures. The failure domain of the entire structural system is computed through the union of failure regions for various critical system failure modes. The effect of non-critical progressive damage is incorporated through structural reanalysis, resulting in the construction of several linear segments to approximately cover the system failure domain. An adaptive damage imposition scheme is outlined for the sake of computational efficiency. The proposed method is used to construct the system survival cdf (cumulative distribution function) of a two-rotor system.
Mahadevan, S.↗
Direct Simulation of Flow over A Wall-Mounted Hump
Simulating separated flows at high Reynolds numbers using Reynolds Averaged Navier-Stokes (RANS) modeled equations remains a challenge in aeronautics. The main hindrance to progress stems from the lack of extended de- tailed data pertinent to the root cause of failure of RANS models, as well as the little progress in RANS modeling innovations in the past several decades. The goal of the current effort is to generate data for separated flow at a Reynolds numbers where conventional models are challenged. We use Direct Numerical Simulations to model turbulent flow over the wall-mounted hump configuration to investigate the physics of flow separation and boundary layer recovery, as well as provide data relevant to the modeling community. A chord-based Reynolds number of Re(sub c) = 47,500 is considered with a turbulent inflow profile of Re(sub θ) = 1,400 (θ /c = 3%). We use FDL3DI, a code that solves the compressible Navier-Stokes equations using high-order compact-difference scheme and filter, with the standard re- cycling/rescaling method of generating turbulent boundary layers as inflow to the computational domain. Two differ- ent configurations of the upper-wall are analyzed for two sets of boundary conditions (slip and no-slip). The results are compared with the available higher Re(sub c) (= 936,000, Re(sub θ) = 7,200, θ /c = 0.77%) experiment for major flow features. The simulated lower Rec allows for DNS-like mesh resolutions, and adequately wide spans. The results from these simulations show earlier separation and delayed reattachment compared to Re(sub c) = 936,000, and significantly higher skin friction in the forebody of the hump. We also find that the upper-wall shape and boundary condition influence pressure distribution over the hump, whereas skin friction is only influenced by the boundary condition.
Wall-Mounted↗
Investigation of Spiral Bevel Gear Condition Indicator Validation Via AC-29-2C Using Damage Progression Tests
This report documents the results of spiral bevel gear rig tests performed under a NASA Space Act Agreement with the Federal Aviation Administration (FAA) to support validation and demonstration of rotorcraft Health and Usage Monitoring Systems (HUMS) for maintenance credits via FAA Advisory Circular (AC) 29-2C, Section MG-15, Airworthiness Approval of Rotorcraft (HUMS) (Ref. 1). The overarching goal of this work was to determine a method to validate condition indicators in the lab that better represent their response to faults in the field. Using existing in-service helicopter HUMS flight data from faulted spiral bevel gears as a "Case Study," to better understand the differences between both systems, and the availability of the NASA Glenn Spiral Bevel Gear Fatigue Rig, a plan was put in place to design, fabricate and test comparable gear sets with comparable failure modes within the constraints of the test rig. The research objectives of the rig tests were to evaluate the capability of detecting gear surface pitting fatigue and other generated failure modes on spiral bevel gear teeth using gear condition indicators currently used in fielded HUMS. Nineteen final design gear sets were tested. Tables were generated for each test, summarizing the failure modes observed on the gear teeth for each test during each inspection interval and color coded based on damage mode per inspection photos. Gear condition indicators (CI) Figure of Merit 4 (FM4), Root Mean Square (RMS), +/- 1 Sideband Index (SI1) and +/- 3 Sideband Index (SI3) were plotted along with rig operational parameters. Statistical tables of the means and standard deviations were calculated within inspection intervals for each CI. As testing progressed, it became clear that certain condition indicators were more sensitive to a specific component and failure mode. These tests were clustered together for further analysis. Maintenance actions during testing were also documented. Correlation coefficients were calculated between each CI, component, damage state and torque. Results found test rig and gear design, type of fault and data acquisition can affect CI performance. Results found FM4, SI1 and SI3 can be used to detect macro pitting on two more gear or pinion teeth as long as it is detected prior to progressing to other components or transitioning to another failure mode. The sensitivity of RMS to system and operational conditions limit its reliability for systems that are not maintained at steady state. Failure modes that occurred due to scuffing or fretting were challenging to detect with current gear diagnostic tools, since the damage is distributed across all the gear and pinion teeth, smearing the impacting signatures typically used to differentiate between a healthy and damaged tooth contact. This is one of three final reports published on the results of this project. In the second report, damage modes experienced in the field will be mapped to the failure modes created in the test rig. The helicopter CI data will then be re-processed with the same analysis techniques applied to spiral bevel rig test data. In the third report, results from the rig and helicopter data analysis will be correlated. Observations, findings and lessons learned using sub-scale rig failure progression tests to validate helicopter gear condition indicators will be presented.
gears↗
Scanning electron microscopy in device diagnostics and reliability physics.
Scanning electron microscopy to study device failure and performance, discussing limitations and progress
Shaw, D. A.↗
An approach to thermal-vacuum test optimization
An analytical model is presented that simulates failure rate characteristics of spacecraft equipment progressing through component and system level thermal-vacuum test programs and on into orbit. Costs for the test programs are part of the model as well as costs attributable to the mission. A lost value function combines the performance of the equipment with these costs and allows comparisons to be made among various test combinations and the resulting predicted mission performance. A minimum overall cost program is obtained by selecting that test program that yields the lowest lost value figure.
Kruger, R.↗
The role of peel stresses in cyclic debonding
When an adhesively bonded joint is undergoing cyclic loading, one of the possible damage modes that occurs is called cyclic debonding - progressive separation of the adherends by failure of the adhesive bond under cyclic loading. In most practical structures, both peel and shear stresses exist in the adhesive bonding during cyclic loading. The results of an experimental and analytical study to determine the role of peel stresses on cyclic debonding in a mixed mode specimen are presented. Experimentally, this was done by controlling the forces that create the peel stresses by applying a clamping force to oppose the peel stresses. Cracked lap shear joints were chosen for this study. A finite element analysis was developed to assess the effect of the clamping force on the strain energy release rates due to shear and peel stresses. The results imply that the peel stress is the principal stress causing cyclic debonding.
Everett, R. A., Jr.↗
SEM/XPS analysis of fractured adhesively bonded graphite fibre-reinforced polyimide composites
The surfaces of the graphite fiber-reinforced polyimide composites presently pretreated prior to bonding with polyimide adhesive contained variable amounts of a fluoropolymer, as determined by X-ray photoelectron spectroscopy. Lap shear strengths were determined for unaged samples and for those aged over 500- and 1000-hour periods at 177 and 232 C. Unaged sample lap strengths, which were the highest obtained, exhibited no variation with surface pretreatment, but a significant decrease is noted with increasing aging temperature. These thermally aged samples, however, had increased surface fluorine concentration, while a minimal concentration was found in unaged samples. SEM demonstrated a progressive shift from cohesive to adhesive failure for elevated temperature-aged composites.
Devilbiss, T. A.↗