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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.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Continued Development of Meandering Winding Magnetometer (MWM (Register Trademark)) Eddy Current Sensors for the Health Monitoring, Modeling and Damage Detection of Composite Overwrapped Pressure Vessels

Composite Overwrapped Pressure Vessels (COPVs) are used in essentially all NASA spacecraft, launch. vehicles and payloads to contain high-pressure fluids for propulsion, life support systems and science experiments. Failure of any COPV either in flight or during ground processing would result in catastrophic damage to the spacecraft or payload, and could lead to loss of life. Therefore, NASA continues to investigate new methods to non-destructively inspect (NDE) COPVs for structural anomalies and to provide a means for in-situ structural health monitoring (SHM) during operational service. Partnering with JENTEK Sensors, engineers at NASA, Kennedy Space Center have successfully conducted a proof-of-concept study to develop Meandering Winding Magnetometer (MWM) eddy current sensors designed to make direct measurements of the stresses of the internal layers of a carbon fiber composite wrapped COPV. During this study three different MWM sensors were tested at three orientations to demonstrate the ability of the technology to measure stresses at various fiber orientations and depths. These results showed good correlation with actual surface strain gage measurements. MWM-Array technology for scanning COPVs can reliably be used to image and detect mechanical damage. To validate this conclusion, several COPVs were scanned to obtain a baseline, and then each COPV was impacted at varying energy levels and then rescanned. The baseline subtracted images were used to demonstrate damage detection. These scans were performed with two different MWM-Arrays. with different geometries for near-surface and deeper penetration imaging at multiple frequencies and in multiple orientations of the linear MWM drive. This presentation will include a review of micromechanical models that relate measured sensor responses to composite material constituent properties, validated by the proof of concept study, as the basis for SHM and NDE data analysis as well as potential improvements including design changes to miniaturize and make the sensors durable in the vacuum of space

Russell, Richard↗
NASA NTRS2013

Design Issues for Using Magnetic Materials in Radiation Environments at Elevated Temperature

One of the challenges of designing motors and alternators for use in nuclear powered space missions is accounting for the effects of radiation. Terrestrial reactor power plants use distance and shielding to minimize radiation damage but space missions must economize volume and mass. Past studies have shown that sufficiently high radiation levels can affect the magnetic response of hard and soft magnetic materials. Theoretical models explaining the radiation-induced degradation have been proposed but not verified. This paper reviews the literature and explains the cumulative effects of temperature, magnetic-load, and radiation-level on the magnetic properties of component materials. Magnetic property degradation is very specific to alloy choice and processing history, since magnetic properties are very much entwined with specific chemistry and microstructural features. However, there is basic theoretical as well as supportive experimental evidence that the negative impact to magnetic properties will be minimal if the bulk temperature of the material is less than fifty percent of the Curie temperature, the radiation flux is low, and the demagnetization field is small. Keywords: Magnets, Permanent Magnets, Power Converters, Nuclear Electric Power Generation, Radiation Tolerance.

Bowman, Cheryl L.↗
NASA NTRSDate not supplied

Fracture of Charring Avcoat With Meshfree Material Response-Coupled Fracture Approach

Fracture of thermal protection systems (TPS) is typically unfavorable, but often unavoidable. TPS can fracture during entry, manufacturing or from impact. Many NASA missions use ablative materials for TPS, including the fore-body for Dragonfly (PICA) and Orion for Artemis-I (Avcoat). The material response to thermal and mechanical loads during entry is integral to TPS sizing, design and analysis. The fracture of TPS also depends, and can be caused by, the change of material properties during entry. Simulations that resolve fracture of TPS due to thermo-mechanical forces can identify TPS failure mechanisms and be applied to conditions inaccessible to ground testing. We present simulation work using a mesh-free/Lagrangian approach to solving continuum mechanics, coupled to material response. Two different materials are simulated under different model entry-like boundary conditions. The dynamic crack structure is analyzed and compared across simulations. Crack analyses inform the role of design features, such as entry trajectories and manufacturing-influenced material properties, play in TPS fracture.

Andrew P Santos↗
NASA NTRSDate not supplied

Multiscale Failure Analysis of a 3D Woven Unit Cell Containing Defects

Multiscale failure simulations have been performed for a Three-dimensional woven composite unit cell considering five, or more, length scales spanning the woven composite mesoscale to the sub-microscale voids. The multiscale recursive micromechanics approach, which enables recursive integration of general micromechanics theories over an arbitrary number of length scales, has been employed within the NASA Multiscale Analysis Tool. The multiscale model uses both the generalized method of cells and Mori-Tanaka micromechanics theories, and considers failure in the constituent materials using a simple damage model. Baseline results, containing distributed voids, are compared to uniaxial experimental data for an AS4 carbon fiber/ RTM6 epoxy matrix 3D orthogonal woven composite with good agreement in terms of global stiffness and global failure stress. The simulations demonstrate that the 3D woven composite exhibits damage tolerance through sustaining increasing axial load far beyond the first initiation of damage. The multiscale model is used to examine the nonlinear response of the material to other loading conditions. Case studies, motivated by X-ray computed tomography data, are presented on the effects of manufacturing induced voids and cracks.

3D woven↗
NASA NTRS1977

Arc heater code validation tests of heat shield materials

Results are reported for tests of candidate heat-shield materials for outer-planet entry probes, which were conducted in two different arc-heater facilities at heating rates below those predicted for entry. One facility supplied a combined radiative-convective heating environment in air while the other provided a hydrogen/helium environment for convective heating only. Both 'infinite-slab' and 'finite-slab' models consisting of various carbon phenolic (CP) and fused silica (FS) materials were tested. The test results obtained are expressed in terms of ablation rates and surface as well as in-depth temperature variations with time for the air environment and in terms of normalized ablation rate as a function of temperature for the H/He environment. The measured values are compared with calculations based on a charring material thermal response and ablation code. For the CP models, good agreement between predicted and measured mass-loss rates is noted, surface temperatures in air are predicted within 18%, and in-depth temperature predictions are shown to be conservative in comparison with measured values. For the FS models, discrepancies are found between the predicted and measured mass-loss rates and surface temperatures.

Kesselring, J. P.↗
NASA NTRS2016

X-ray Micro-Tomography of Ablative Heat Shield Materials

X-ray micro-tomography is a non-destructive characterization technique that allows imaging of materials structures with voxel sizes in the micrometer range. This level of resolution makes the technique very attractive for imaging porous ablators used in hypersonic entry systems. Besides providing a high fidelity description of the material architecture, micro-tomography enables computations of bulk material properties and simulations of micro-scale phenomena. This presentation provides an overview of a collaborative effort between NASA Ames Research Center and Lawrence Berkeley National Laboratory, aimed at developing micro-tomography experiments and simulations for porous ablative materials. Measurements are carried using x-rays from the Advanced Light Source at Berkeley Lab on different classes of ablative materials used in NASA entry systems. Challenges, strengths and limitations of the technique for imaging materials such as lightweight carbon-phenolic systems and woven textiles are discussed. Computational tools developed to perform numerical simulations based on micro-tomography are described. These enable computations of material properties such as permeability, thermal and radiative conductivity, tortuosity and other parameters that are used in ablator response models. Finally, we present the design of environmental cells that enable imaging materials under simulated operational conditions, such as high temperature, mechanical loads and oxidizing atmospheres.Keywords: Micro-tomography, Porous media, Ablation

tomography↗
NASA NTRS2010

Investigation of a Macromechanical Approach to Analyzing Triaxially-Braided Polymer Composites

A macro level finite element-based model has been developed to simulate the mechanical and impact response of triaxially-braided polymer matrix composites. In the analytical model, the triaxial braid architecture is simulated by using four parallel shell elements, each of which is modeled as a laminated composite. The commercial transient dynamic finite element code LS-DYNA is used to conduct the simulations, and a continuum damage mechanics model internal to LS-DYNA is used as the material constitutive model. The material stiffness and strength values required for the constitutive model are determined based on coupon level tests on the braided composite. Simulations of quasi-static coupon tests of a representative braided composite are conducted. Varying the strength values that are input to the material model is found to have a significant influence on the effective material response predicted by the finite element analysis, sometimes in ways that at first glance appear non-intuitive. A parametric study involving the input strength parameters provides guidance on how the analysis model can be improved.

Goldberg, Robert K.↗
NASA NTRS1992

An evaluation of mixed-mode delamination failure criteria

Many different failure criteria have been suggested for mixed mode delamination toughness, but few sets of mixed mode data exist that are consistent over the full mode I opening to mode II shear load range. The mixed mode bending (MMB) test was used to measure the delamination toughness of a brittle epoxy composite, a state of the art toughened epoxy composite, and a tough thermoplastic composite over the full mixed mode range. To gain insight into the different failure responses of the different materials, the delamination fracture surfaces were also examined. An evaluation of several failure criteria which have been reported in the literature was performed, and the range of responses modeled by each criterion was analyzed. A new bilinear failure criterion was analyzed. A new bilinear failure criterion was developed based on a change in the failure mechanism observed from the delamination surfaces. The different criteria were compared to the failure criterion. The failure response of the tough thermoplastic composite could be modeled well with the bilinear criterion but could also be modeled with the more simple linear failure criterion. Since the materials differed in their mixed mode failure response, mixed mode delamination testing will be needed to characterize a composite material. A critical evaluation is provided of the mixed mode failure criteria and should provide general guidance for selecting an appropriate criterion for other materials.

Reeder, J. R.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-33512-DND

INTRODUCTION: In an effort to quantify the predictive capability of the Livermore Software Technology Corporation (LSTC)-provided Hybrid III (small female, mid-size male, and large male) anthropomorphic test device (ATD) finite element models (FEMs) within aerospace loading environments, the National Aeronautics and Space Administration (NASA) performed a series of sled tests with the isolated head-neck complex of each ATD. These tests and subsequent modeling efforts revealed significant deficiencies in the large male head neck FEM. Differences in both the shape and material properties between the FEM and the physical ATD were identified. In order to improve the predictive response of the FEM, a model development effort was undertaken to update the head-neck complex to better represent the geometric and material properties of the physical ATD.METHODS: To better match the physical geometry, a new neck component model was meshed and implemented into the Hybrid III large male head-neck complex. The updated geometry and weight were verified against measurements of the physical ATD to insure accuracy. The primary source of material discrepancy between the physical ATD and FEM was found to be in the material definition of the rubber neck pucks. Using LS-Opt the material properties of this part were calibrated to match physical response of the head-neck complex in the isolated head-neck testing performed. RESULTS AND DISCUSSION: The updated geometry and calibrated material properties were shown to significantly improve the FEM predictive accuracy under lateral, rear, and frontal impacts with combined horizontal and vertical loading. The results of this study demonstrate an effective means for improving ATD FEM response through isolated component level testing and material parameter optimization. The improved and quantified accuracy of the Hybrid III large male FEM head-neck complex stemming from with work lends to confidence in its future use for occupant protection evaluation of large male occupants

J Putnam↗
NASA NTRS2016

Heatshield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASAs high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50 mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in its 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

Thermal Protection System↗
NASA NTRS2016

Heat-shield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASA's high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50% mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in it's 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to-date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

TPS↗
NASA NTRSDate not supplied

AI-Enhanced Computational Tools for Entry Systems Modeling

To advance the understanding of complex atmospheric entry phenomena, NASA’s Entry Systems Modeling (ESM) team [1] has developed high-fidelity computational tools addressing multiscale challenges, from material microstructures to full-scale heatshield response. This abstract highlights a subset of ESM tools, focusing on AI integration to enhance workflows and predictive modeling. - PuMA [2] computes effective material properties from high-resolution micro-CT scans, supporting TPS analysis for NASA missions. - TomoSAM [3] automates 3D tomography dataset segmentation for PuMA using the Segment Anything Model, reducing manual effort and improving accuracy. - PATO [4] models porous reactive materials under extreme conditions, with advancements such as unified solvers, mechanical erosion, and TPS coatings for NASA missions. - arcjetCV [5] employs deep learning to analyze arc jet test footage, measuring recession rates, shape changes, and shock standoff distances, bridging simulations, and experiments to reveal TPS ablation behavior. - ARCHeS [6] simulates arc heater plasma flows, modeling turbulence, radiation, and electromagnetic interactions to optimize arc heater performance, validate TPS under extreme conditions, and serve as a foundation for developing digital twins of arc heater facilities. - SPARTA [7] simulates rarefied hypersonic flows and gas-surface interactions for planetary entry missions, leveraging GPU architectures for scalable and efficient aerothermal and ablation analyses. AI-driven solutions, such as deep learning segmentation, have streamlined workflows in ESM tools and still hold significant potential to further accelerate processes and enhance automation in entry systems modeling. [1] Haskins, J.B. (2023), [2] Ferguson, J.C. (2018), [3] Meurisse, J.B.E. (2018), [4] Semeraro, F. (2023), [5] Quintart, A. (2024) [6] Meurisse, J.B.E. (2022), [7] Plimpton, S.J. (2019)

Predictive Modeling↗
NASA NTRSDate not supplied

Application of the MAT 213 Composite Impact Model to NASA Problems of Interest

A material model has been developed which incorporates several key capabilities which have been identified as lacking in currently available composite impact models. The material model utilizes experimentally based tabulated input to define the evolution of plasticity and damage as opposed to specifying discrete input parameters (such as modulus and strength). The material model has been implemented into LS-DYNA® as MAT 213. The model can simulate the nonlinear deformation, damage and failure that takes place in a composite under dynamic loading conditions. The deformation model utilizes an orthotropic plasticity formulation. For the damage model, the nonlinear unloading response that is observed prior to the point where the peak stress is reached can be simulated, as well as the stress degradation response that occurs after the peak stress is reached. A variety of failure models, including a generalized tabulated failure model which facilitates the utilization of general failure surfaces, have been implemented into MAT 213. Recent studies at NASA have concentrated on using MAT 213 to analyze both the impact and crush response of a variety of laminated and textile architectures. Several of these studies will be discussed in the presented paper. For example, a woven carbon/Kevlar composite is currently being examined for use in an energy absorber system for rotorcraft structures. MAT 213 analyses have been conducted to examine the ability of the model to accurately simulate the dynamic crush response of this material. Studies are also being conducted to examine the ability of MAT 213 to simulate the ballistic impact response of representative laminated and woven thermoplastic and thermoset matrix composites. NASA efforts are also concentrated on developing methods and processes for improving characterization methods and developing “best practices” for using MAT 213, a summary of which will be discussed in the paper.

Polymer Matrix Composites↗
NASA NTRS2018

Modeling the Proton Radiation Belt With Van Allen Probes Relativistic Electron-Proton Telescope Data

An empirical model of the proton radiation belt is constructed from data taken during 2013-2017 by the Relativistic Electron-Proton Telescopes on the Van Allen Probes satellites. The model intensity is a function of time, kinetic energy in the range 18-600 megaelectronvolts, equatorial pitch angle, and L shell of proton guiding centers. Data are selected, on the basis of energy deposits in each of the nine silicon detectors, to reduce background caused by hard proton energy spectra at low L. Instrument response functions are computed by Monte Carlo integration, using simulated proton paths through a simplified structural model, to account for energy loss in shielding material for protons outside the nominal field of view. Overlap of energy channels, their wide angular response, and changing satellite orientation require the model dependencies on all three independent variables be determined simultaneously. This is done by least squares minimization with a customized steepest descent algorithm. Model uncertainty accounts for statistical data error and systematic error in the simulated instrument response. A proton energy spectrum is also computed from data taken during the 8 January 2014 solar event, to illustrate methods for the simpler case of an isotropic and homogeneous model distribution. Radiation belt and solar proton results are compared to intensities computed with a simplified, on-axis response that can provide a good approximation under limited circumstances.

Selesnick, R. S.↗
NASA NTRS2016

Fatigue Analysis of Notched Laminates: A Time-Efficient Macro-Mechanical Approach

A coupled transversely isotropic deformation and damage fatigue model is implemented within the finite element method and was utilized along with a static progressive damage model to predict the fatigue life, stiffness degradation as a function of number of cycles, and post-fatigue tension and compression response of notched, multidirectional laminates. Initially, the material parameters for the fatigue model were obtained utilizing micromechanics simulations and the provided [0], [90] and [plus or minus 45] experimental composite laminate S-N (stress-cycle) data. Within the fatigue damage model, the transverse and shear properties of the plies were degraded with an isotropic scalar damage variable. The damage in the longitudinal (fiber) ply direction was suppressed, and only the strength of the fiber was degraded as a function of fatigue cycles. A maximum strain criterion was used to capture the failure in each element, and once this criterion was satisfied, the longitudinal stiffness of the element was decreased by a factor of 10 (sup 4). The resulting, degraded properties were then used to calculate the new stress state. This procedure was repeated until final failure of the composite laminate was achieved or a specified number of cycles reached. For post-fatigue tension and compression behavior, four internal state variables were used to control the damage and failure. The predictive capability of the above-mentioned approach was assessed by performing blind predictions of the notched multidirectional IM7/977-3 composite laminates response under fatigue and post-fatigue tensile and compressive loading, followed by a recalibration phase. Although three different multidirectional laminates were analyzed in the course of this study, only detailed results (i.e., stiffness degradation and post-fatigue stress-train curves as well as damage evolution states for a single laminate ([30/60/90/minus 30/minus 60] (sub 2s)) are discussed in detail here.

Composite Fatigue analysis↗
NASA NTRS2001

Thermal/Pyrolysis Gas Flow Analysis of Carbon Phenolic Material

Provided in this study are predicted in-depth temperature and pyrolysis gas pressure distributions for carbon phenolic materials that are externally heated with a laser source. Governing equations, numerical techniques and comparisons to measured temperature data are also presented. Surface thermochemical conditions were determined using the Aerotherm Chemical Equilibrium (ACE) program. Surface heating simulation used facility calibrated radiative and convective flux levels. Temperatures and pyrolysis gas pressures are predicted using an upgraded form of the SINDA/CMA program that was developed by NASA during the Solid Propulsion Integrity Program (SPIP). Multispecie mass balance, tracking of condensable vapors, high heat rate kinetics, real gas compressibility and reduced mixture viscosity's have been added to the algorithm. In general, surface and in-depth temperature comparisons are very good. Specie partial pressures calculations show that a saturated water-vapor mixture is the main contributor to peak in-depth total pressure. Further, for most of the cases studied, the water-vapor mixture is driven near the critical point and is believed to significantly increase the local heat capacity of the composite material. This phenomenon if not accounted for in analysis models may lead to an over prediction in temperature response in charring regions of the material.

Clayton, J. Louie↗
NASA NTRS2003

Universal Responses of Cyclic-Oxidation Models Studied

Oxidation is an important degradation process for materials operating in the high-temperature air or oxygen environments typical of jet turbine or rocket engines. Reaction of the combustion gases with the component material forms surface layer scales during these oxidative exposures. Typically, the instantaneous rate of reaction is inversely proportional to the existing scale thickness, giving rise to parabolic kinetics. However, more realistic applications entail periodic startup and shutdown. Some scale spallation may occur upon cooling, resulting in loss of the protective diffusion barrier provided by a fully intact scale. Upon reheating, the component will experience accelerated oxidation due to this spallation. Cyclic-oxidation testing has, therefore, been a mainstay of characterization and performance ranking for high-temperature materials. Models simulate this process by calculating how a scale spalls upon cooling and regrows upon heating (refs. 1 to 3). Recently released NASA software (COSP for Windows) allows researchers to specify a uniform layer or discrete segments of spallation (ref. 4). Families of model curves exhibit consistent regularity and trends with input parameters, and characteristic features have been empirically described in terms of these parameters. Although much insight has been gained from experimental and model curves, no equation has been derived that can describe this behavior explicitly as functions of the key oxidation parameters.

Smialek, James L.↗
NASA NTRS2013

Experimental and Analytical Characterization of the Macromechanical Response for Triaxial Braided Composite Materials

Increasingly, carbon composite structures are being used in aerospace applications. Their highstrength, high-stiffness, and low-weight properties make them good candidates for replacing many aerospace structures currently made of aluminum or steel. Recently, many of the aircraft engine manufacturers have developed new commercial jet engines that will use composite fan cases. Instead of using traditional composite layup techniques, these new fan cases will use a triaxially braided pattern, which improves case performance. The impact characteristics of composite materials for jet engine fan case applications have been an important research topic because Federal regulations require that an engine case be able to contain a blade and blade fragments during an engine blade-out event. Once the impact characteristics of these triaxial braided materials become known, computer models can be developed to simulate a jet engine blade-out event, thus reducing cost and time in the development of these composite jet engine cases. The two main problems that have arisen in this area of research are that the properties for these materials have not been fully determined and computationally efficient computer models, which incorporate much of the microscale deformation and failure mechanisms, are not available. The research reported herein addresses some of the deficiencies present in previous research regarding these triaxial braided composite materials. The current research develops new techniques to accurately quantify the material properties of the triaxial braided composite materials. New test methods are developed for the polymer resin composite constituent and representative composite coupons. These methods expand previous research by using novel specimen designs along with using a noncontact measuring system that is also capable of identifying and quantifying many of the microscale failure mechanisms present in the materials. Finally, using the data gathered, a new hybrid micromacromechanical computer model is created to simulate the behavior of these composite material systems under static and ballistic impact loading using the test data acquired. The model also quantifies the way in which the fiber/matrix interface affects material response under static and impact loading. The results show that the test methods are capable of accurately quantifying the polymer resin under a variety of strain rates and temperature for three loading conditions. The resin strength and stiffness data show a clear rate and temperature dependence. The data also show the hydrostatic stress effects and hysteresis, all of which can be used by researchers developing composite constitutive models for the resins. The results for the composite data reveal noticeable differences in strength, failure strain, and stiffness in the different material systems presented. The investigations into the microscale failure mechanisms provide information about the nature of the different material system behaviors. Finally, the developed computer model predicts composite static strength and stiffness to within 10 percent of the gathered test data and also agrees with composite impact data, where available.

Littell, Justin D.↗