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The general goals of the research program are to characterize alloy behavior quantitatively and to develop predictive mechanisms for environmental failure modes. Successes in this regard will provide the basis for metallurgical optimization of alloy performance, for chemical control of aggressive environments, and for engineering life prediction with damage tolerance and long term reliability.
A multifaceted research program on the performance of advanced light metallic alloys in aggressive aerospace environments, and associated environmental failure mechanisms was initiated. The general goal is to characterize alloy behavior quantitatively and to develop predictive mechanisms for environmental failure modes. Successes in this regard will provide the basis for metallurgical optimization of alloy performance, for chemical control of aggressive environments, and for engineering life prediction with damage tolerance and long term reliability.
The National Aeronautics and Space Administration is developing graphite/epoxy filament-wound cases (FWC) for the solid rocket motors of the Space Shuttle. The membrane region is about 36 mm thick. A study was made to determine the reduction in strength of the FWC due to accidental damage caused by low-velocity impacts. Two 76.2 cm diameter by 30.5 cm long cylinders were impacted every 5 cm of circumference with 1.27 cm radius impacters of various mass. The impacters represented tools and equipment dropped from various heights. One cylinder was empty and the other was filled with inert propellant. Five cm wide test specimens were cut from the cylinder. Each was centered on an impact site. The specimens were X-rayed and loaded to failure in uniaxial tension. The strengths and depths of impact damage were analyzed in terms of maximum impact force. Rigid body mechanics and the Hertz law were used to derive an equation for impact force in terms of kinetic energy and the masses of the impacter and target. The depth of damage was predicted in terms of impact force using Love's solution of pressure applied on part of the boundary of a semi-infinite body.
A finite element micromechanics approach was utilized to investigate the thermally induced stress fields in continuous fiber reinforced polymer matrix composites at temperatures typical of spacecraft operating environments. The influence of laminate orientation was investigated with a simple global/local formulation. Thermal stress calculations were used to predict probable damage initiation locations, and the results were compared to experimentally observed damage in several epoxy matrix composites. The influence of an interphase region on the interfacial stress states was investigated.
A progressive failure analysis method has been developed for predicting the failure of laminated composite structures under geometrically nonlinear deformations. The progressive failure analysis uses C(exp 1) shell elements based on classical lamination theory to calculate the in-plane stresses. Several failure criteria, including the maximum strain criterion, Hashin's criterion, and Christensen's criterion, are used to predict the failure mechanisms and several options are available to degrade the material properties after failures. The progressive failure analysis method is implemented in the COMET finite element analysis code and can predict the damage and response of laminated composite structures from initial loading to final failure. The different failure criteria and material degradation methods are compared and assessed by performing analyses of several laminated composite structures. Results from the progressive failure method indicate good correlation with the existing test data except in structural applications where interlaminar stresses are important which may cause failure mechanisms such as debonding or delaminations.
Computational simulation results can give the prediction of damage growth and progression and fracture toughness of composite structures. The experimental data from literature provide environmental effects on the fracture behavior of metallic or fiber composite structures. However, the traditional experimental methods to analyze the influence of the imposed conditions are expensive and time consuming. This research used the CODSTRAN code to model the temperature effects, scaling effects and the loading effects of fiberbraided composite specimens with and without fiber-optic sensors on the damage initiation and energy release rates. The load-displacement relationship and fracture toughness assessment approach is compared with the test results from literature and it is verified that the computational simulation, with the use of established material modeling and finite element modules, adequately tracks the changes of fracture toughness and subsequent fracture propagation for any fiberbraided composite structure due to the change of fiber orientations, presence of large diameter optical fibers, and any loading conditions.
Computational simulation results can give the prediction of damage growth and progression and fracture toughness of composite structures. The experimental data from literature provide environmental effects on the fracture behavior of metallic or fiber composite structures. However, the traditional experimental methods to analyze the influence of the imposed conditions are expensive and time consuming. This research used the CODSTRAN code to model the temperature effects, scaling effects and the loading effects of fiber/braided composite specimens with and without fiber-optic sensors on the damage initiation and energy release rates. The load-displacement relationship and fracture toughness assessment approach is compared with the test results from literature and it is verified that the computational simulation, with the use of established material modeling and finite element modules, adequately tracks the changes of fracture toughness and subsequent fracture propagation for any fiber/braided composite structure due to the change of fiber orientations, presence of large diameter optical fibers, and any loading conditions.
A progressive failure analysis methodology has been developed for predicting the nonlinear response and failure of laminated composite structures. The progressive failure analysis uses C plate and shell elements based on classical lamination theory to calculate the in-plane stresses. Several failure criteria, including the maximum strain criterion, Hashin's criterion, and Christensen's criterion, are used to predict the failure mechanisms. The progressive failure analysis model is implemented into a general purpose finite element code and can predict the damage and response of laminated composite structures from initial loading to final failure.
Fatigue crack growth tests were conducted to characterize the performance of Inconel 718 and CRES 321 welds, weld heat-affect-zone and parent metal at room temperature laboratory air and liquid nitrogen (-196oC) environments. The results of this study were required to predict the damage tolerance behavior of proposed orbiter main engine hydrogen fuel liner weld repairs. Experimental results show that the room and cryogenic temperature fatigue crack growth characteristics of both alloys are not significantly degraded by the weld repair process. However, both Inconel 718 and CRES 321 exhibited lower apparent toughness within the weld repair region compared to the parent metal.
A variable fidelity, multiscale, physics based finite element procedure for predicting progressive damage and failure of laminated continuous fiber reinforced composites is introduced. At every integration point in a finite element model, progressive damage is accounted for at the lamina-level using thermodynamically based Schapery Theory. Separate failure criteria are applied at either the global-scale or the microscale in two different FEM models. A micromechanics model, the Generalized Method of Cells, is used to evaluate failure criteria at the micro-level. The stress-strain behavior and observed failure mechanisms are compared with experimental results for both models.
NASA's aeronautical research not only encompasses advancing aircraft technology and aviation safety for today and the future, but it also has a branch that deals with Airborne Science. This Airborne Science branch possesses unique airborne flight vehicles (manned and unmanned) whose sole purpose is to take scientists and their experiments anywhere in the world, into nearly any climatic condition, to gather the data they need for their research. This research spans such fields as; global warming, weather analysis, air and water pollution, mineral and archaeology search, earthquake damage and prediction, and yes, hurricanes. The data we obtain will hopefully, one day, allow us to better understand our planet, its natural forces and man's interaction with them.
Over the past decade, the Agency has placed less emphasis on testing and has increasingly relied on computational methods to assess durability and damage tolerance (D&DT) behavior when evaluating design margins for fracture-critical components. With increased emphasis on computational D&DT methods as the standard practice, it is paramount that capabilities of these methods are understood, the methods are used within their technical limits, and validation by well-designed tests confirms understanding. The D&DT performance of a component is highly dependent on parameters in the neighborhood of the damage. This report discusses D&DT method vulnerabilities.
Single fiber-tow minicomposites represent the major load-bearing element of woven and laminate ceramic matrix composites (CMCs). To understand the effects of fiber type, fiber content, and matrix cracking on tensile creep in SiCf/SiC CMCs, single-tow SiCf/SiC minicomposites with different fiber types and contents were investigated. The minicomposites studied contained either Hi-Nicalon™ or Hi-Nicalon™ Type S SiC fibers with a boron nitride (BN) interphase and a chemical-vapor-infiltrated-silicon-carbide (CVI-SiC) matrix. Tensile creep was performed at 1200 °C in air. A bottom-up creep modeling approach was applied where creep parameters of the fibers and matrix were obtained separately at 1200 °C. Next, a theoretical model based on the rule of mixtures was derived to model the fiber and matrix creep-time-dependent stress redistribution. Fiber and matrix creep parameters, load transfer model results, and numerical modeling were used to construct a creep strain model to predict creep damage evolution of minicomposites with different fiber types and contents.
An artificial convolutional neural network was created to efficiently mimic a micromechanics model, the High Fidelity Generalized Method of Cells, for use in multi-scale structural finite element analysis. The network was found to quickly and accurately replicate the stiffness predicted by the micromechanics model using a 2D image of an idealized representative volume element of a fiber/matrix microstructure. The long-term goal of this work is to efficiently apply multi-scale methods for predicting the damage progression of a composite structure.
The impact damage resistance and damage tolerance of graphite/epoxy fabric plate (coupon) and cylinder structures were investigated and compared in an analytical and experimental study. Hercules A370-5H/3501-6 five-harness satin weave cloth in a quasi-isotropic (0,45)(sub s) laminate configuration was utilized. Specimens were impacted with 12.7 mm diameter steel spheres at velocities ranging from 10 m/s to 100 m/s. Damage resistance of the specimens was determined through the use of dye penetrant enhanced x-radiography, sectioning, epoxy burnoff, and visual methods. Damage tolerance of the flat plate structures was assessed in a residual tensile test while damage tolerance of the cylinder structures was assessed via pressurization tests. Impacted fabric laminates exhibited matrix crushing, fiber breakage, delamination, and fiber bundle disbonds; the latter being a unique damage mode for fabric laminates. Plate delamination and bundle disbonding was found to be more extensive around the central core area of fiber damage in the coupon specimens than in the cylinder specimens which showed a cleaner damage area due to impact. Damage resistance and damage tolerance were predicted by utilizing a five-step analysis approach previously utilized for coupon configurations. Two of the five steps were adapted to account for the effects of the structural configuration of the pressurized cylinder. The damage resistance analysis provided good correlation to the fiber damage region of both the coupon and cylinder specimens. There was little difference in the size of this region in the two specimen types. However, the analysis was not able to predict the distribution of damage through-the-thickness. This was important in assessing the damage tolerance of the cylinders. The damage tolerance analysis was able to predict the residual tensile strength of the coupons. A general methodology to predict the impact damage resistance and damage tolerance of composite structures utilizing coupon data is presented.
Divertor design and choice of plasma-facing materials (PFM) will be essential to the success of next-generation fusion reactors as they operate under more powerful scenarios. Understanding and controlling interactions between the plasma and PFM is essential to making these choices. Within these plasma–material interactions and especially in tungsten (W), the interplay between the most abundant plasma species (hydrogen isotopes and helium, He) with the wall material alters fuel retention. However, this interplay is yet to be sufficiently understood to confidently project fuel retention levels to future fusion devices. The paper presents a series of integrated simulations of fusion plasmas and their interaction with tungsten. Specifically, this study assesses the impact of He plasma pre-exposure on hydrogenic species retention during 100 s of burning plasma operations (BPO) in ITER. Multiple pre-exposure scenarios are considered, including sub-surface damage resulting from exposures in the linear device PISCES and from early ITER He-operation. The predictions from these consecutive He-BPO exposures show that fuel content and spatial distribution in the material are largely determined by the He-induced damage, as manifest in: (i) changes in surface temperature expected during BPO have little effect on fuel retention in the presence of He-induced damage; (ii) gas content stabilizes quickly in substrates pre-exposed in PISCES, at levels set by the concentration of pre-existing vacancies, while it continues to increase in substrates initially pristine or pre-exposed to ITER He plasmas; (iii) the presence of He and He–V clusters in the near-surface region locally increases hydrogenic retention, but decreases its permeation; this results in hydrogenic species that remain closer to the surface in pre-damaged substrates, while the bulk content is higher for initially pristine cases. In summary, the interaction and binding of D and T with the pre-existing He–V clusters modifies retention and permeation of hydrogen species during ITER BPO.
Crack initiation prediction in high temperature components subjected to arbitrary thermal- mechanical cycling
Nuclear-grade graphites are used extensively in the core designs of multiple types of advanced nuclear reactors. In the reactor environment, graphite is exposed over long durations to extreme conditions, including high temperatures, radiation and potentially molten salt and oxygen. Exposure to these conditions can cause several degradation mechanisms in graphite, including nonuniform volumetric strains induced by irradiation and thermal expansion, which lead to stresses that can compromise the performance of graphite components. Evaluating component integrity, predicting component performance over the reactor lifetime, and developing design standards all require robust tools for predicting fracture initiation and propagation in graphite structural components in nuclear reactors. This report documents progress in an ongoing effort to develop modeling and simulation tools in the Grizzly code for predicting the performance of graphite exposed to reactor conditions. Recent developments include a set of thermal and mechanical models that now include the IG-110, NBG-18, and H-451 graphite grades. Improvements have also been made to a nonlinear damaged plasticity model applicable to predicting damage under tension and compression to quasibrittle materials, including graphite. In addition, enhancements have been made to the extended finite element method implementation targeted at simulating graphite fracture. These include new capabilities for crack nucleation in the interior of a solid body, improved treatment of crack nucleation on free surfaces, and more robust modeling approaches for crack growth approaching free surfaces or other cracks.