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DOE OSTI2023

Universal Maximum Strength of Solid Metals and Alloys

As described here, interstitial electron density ρ o is offered as a direct metric for maximum strength in metals, arising from universal properties derived from an electron-gas – ρ o sets the exchange-correlation parameter r s in density-functional theory (DFT). It holds also for maximum shear strength τ max in polycrystals [Phys. Rev. Lett. 124, 125501]. Elastic moduli and τ max for polycrystalline (amorphous) metals are linear with ρ o and melting T m (glass-transition T g ) temperature. ρ o or r s , even with rule-of-mixture estimate, predicts relative strength for rapid, reliable selection of high-strength alloys with ductility, as confirmed for elements to steels to complex solid-solutions, and validated experimentally.

36 MATERIALS SCIENCE↗

NASA NTRS1981

Design, fabrication and test of graphite/polyimide composite joints and attachments for advanced aerospace vehicles

The development of several types of graphite/polyimide (GR/PI) bonded and bolted joints is reported. The program consists of two concurrent tasks: (1) design and test of specific built up attachments; and (2) evaluation of standard advanced bonded joint concepts. A data base for the design and analysis of advanced composite joints for use at elevated temperatures (561K (550 deg F)) to design concepts for specific joining applications, and the fundamental parameters controlling the static strength characteristics of such joints are evaluated. Data for design and build GR/PI of lightly loaded flight components for advanced space transportation systems and high speed aircraft are presented. Results for compression and interlaminar shear strengths of Celion 6000/PMR-15 laminates are given. Static discriminator test results for type 3 and type 4 bonded and bolted joints and final joint designs for TASK 1.4 scale up fabrication and testing are presented.

Source record↗

DOE OSTI2021

IACMI Project 4.2: Thermoplastic Composite Development for Wind Turbine Blades

(Section 5.1) Composites made from Arkema’s Elium® thermoplastic resin and Johns Manville fiberglass were researched during this project for applications in wind blade manufacturing. A techno-economic model was developed to model this wind blade manufacturing process using these materials in place of traditional composites made with thermoset resin. This model was based on manufacturing a 61.5-meter wind blade, which showed a 4.7% reduction in wind blade cost as compared traditional thermoset materials. These cost savings were not from the thermoplastic material costing less than traditional thermoset materials, but rather from decreased capital costs, faster cycle times and reduced energy requirements and labor costs. (Section 5.2) An infusion and curing model was developed for thermoplastic composite wind blades using PAM-RTM. The primary goal was to demonstrate the infusion simulation for the Elium® resin system on a 13-meter wind blade. Additionally, the exotherm temperature was predicted and compared to measurements, which showed model results within 10% of actual measurements. (Section 5.3) Composite laminate panels and composite sandwich panels with a balsa core were produced; specimens were cut and characterized. Similar composite specimens were made with Elium® thermoplastic resin and Hexion thermoset epoxy (RIMR135/RIMH1366) to enable comparisons between these resin systems. The static test methods included: tensile, compression, in-plane shear, interlaminar shear, flexural, sandwich core shear flexure, and single cantilever beam tests for sandwich beams. Fatigue testing at room temperature was completed to composite laminate panels at a stress ratio of R=0.1 and R=10. In addition, fatigue testing to laminate panels was completed at -30°C, and at room temperature after conditioning specimens at 70°C and 90% relative humidity. Overall, mechanical test results from Elium® composites are similar to epoxy composites. (Section 5.4) Elium composite panels were produced with intentional defects such as voids and nonwetting of fibers to begin to understand performance sensitivity to defects. A thermal digital image correlation (TDIC) method provides high spatial resolution strain field at elevated temperatures and can be used to identify defective regions within composite panels. Flexural modulus differences of 21% were seen between defect and non-defect panels. Other Elium® composite panels were forced to be defective by boiling the resin after infusion, which created voids throughout the composite laminate. X-ray computed tomography scanning was used to view the internal structure of the defect panels. Defect panels had a significant reduction in fatigue life as compared to baseline panels produced without intentional defects. (Section 5.5) Lap shear specimens were fabricated to compare the lap shear strength of an off-the-shelf adhesive (Plexus MA590) and two new adhesives developed by Arkema (Bostik SAF30 90 and Bostik SAF30 120). ISO standard 4587:2003 was used to standardize the testing method and sample fabrication. Lap shear specimens were made at 1mm, 3mm, and 10mm thicknesses. The Bostik adhesive lap shear test results were similar to Plexus for all thicknesses. (Section 5.6) Fiber-reinforced polymer (FRP) composites are typically used in high-performance applications (e.g., aerospace), and their expansion into high-volume industries (e.g. consumer automotive and wind turbine blade manufacturer or similar) is hindered by their cost and a lack of efficient manufacturing techniques. Monitoring the curing process of these composites during manufacturing can improve the efficiency of the process, and therefore reduce the manufacturing cost. Cure monitoring techniques were developed that use probabilistic estimation methods and surface temperature measurements made using infrared cameras. These techniques enable real-time monitoring of the infusion process to locate manufacturing flaws, and they can, potentially, estimate residual stresses in the part. Their commercialization will help facilitate expansion of FRP composites in high-volume industries. (Section 5.7) A 13-meter composite wind blade was produced with Elium® resin and Johns Manville fiberglass; this blade was made with VARTM processing similar to how megawatt-scale wind blades are currently manufactured, but no post-mold heating was used for this thermoplastic composite blade. The wind blade underwent full-scale validation for static loading (4-different load orientations) and flapwise fatigue loading to simulate 20-years of operational loads. The thermoplastic composite wind blade withstood the loading without any noted issues and performed similar to results from a previous full-scale validation to an equivalent epoxy composite wind blade produced with the same blade molds. (Section 5.8) A study was conducted to determine the feasibility of recycling composite wind turbine blade components fabricated with glass fiber reinforced Elium® thermoplastic resin. Dissolution, which is a process unique to thermoplastic matrices, allows recovery of both the polymer matrix and full-length glass fibers, while maintaining their stiffness and strength throughout the recovery process. The economics of recycling is favorable if 50% of the glass fiber is recovered and resold for a process of $\$$ 0.28/kg, and 90% of the resin is recovered and resold at a price of $\$$ 2.50/kg.(Section 10) Recommendations are outlined for commercializing thermoplastic resin for composite wind blade production, in addition to recommended areas for future research.

17 WIND ENERGY↗

NASA NTRS1990

Intrinsic bond strength of metal films on polymer substrates

A semiquantitative method for the measurement of the intrinsic bond strength between elastic substrates and elastic films that fail by brittle fracture is described. Measurements on a polyethylene terephthalate (PET)-Ni couple were used to verify the essential features of the analysis. It was found that the interfacial shear strength of Ni on PET doubled after ion etching.

Wheeler, Donald R.↗

NASA NTRS2011

Single Piezo-Actuator Rotary-Hammering Drill

This innovation comprises a compact drill that uses low-axial preload, via vibrations, that fractures the rock under the bit kerf, and rotates the bit to remove the powdered cuttings while augmenting the rock fracture via shear forces. The vibrations fluidize the powered cuttings inside the flutes around the bit, reducing the friction with the auger surface. These combined actions reduce the consumed power and the heating of the drilled medium, helping to preserve the pristine content of the produced samples. The drill consists of an actuator that simultaneously impacts and rotates the bit by applying force and torque via a single piezoelectric stack actuator without the need for a gearbox or lever mechanism. This reduces the development/fabrication cost and complexity. The piezoelectric actuator impacts the surface and generates shear forces, fragmenting the drilled medium directly under the bit kerf by exceeding the tensile and/or shear strength of the struck surface. The percussive impact action of the actuator leads to penetration of the medium by producing a zone of finely crushed rock directly underneath the struck location. This fracturing process is highly enhanced by the shear forces from the rotation and twisting action. To remove the formed cuttings, the bit is constructed with an auger on its internal or external surface. One of the problems with pure hammering is that, as the teeth become embedded in the sample, the drilling efficiency drops unless the teeth are moved away from the specific footprint location. By rotating the teeth, they are moved to areas that were not fragmented, and thus the rock fracturing is enhanced via shear forces. The shear motion creates ripping or chiseling action to produce larger fragments to increase the drilling efficiency, and to reduce the required power. The actuator of the drill consists of a piezoelectric stack that vibrates the horn. The stack is compressed by a bolt between the backing and the horn in order to prevent it from being subjected to tensile stress that will cause it to fail. The backing is intended to transfer the generated mechanical vibrations towards the horn. In order to cause rotation, the horn is configured asymmetrically with helical segments and, upon impacting the bit, it introduces longitudinal along the axis of the actuator and tangential force causing twisting action that rotates the bit. The longitudinal component of the vibrations of the stack introduces percussion impulses between the bit and the rock to fracture it when the ultimate strain is exceeded under the bit.

Sherrit, Stewart↗

DOE OSTI2024

Utah FORGE: Temperature-Dependent Fracture Seismicity from Fluid Injection Experiments

This dataset contains experimental data from fluid injection experiments conducted to investigate the influence of temperature on fracture seismicity. The experiments were performed on granite samples from Utah FORGE. The samples were prepared with a 30-degree inclined fracture and subjected to controlled stress and temperature conditions. Data were collected under three distinct temperature settings: 24 C, 78 C, and 137 C. During the experiments, a constant confining pressure of 10 MPa and a constant shear stress at 80% of the shear strength of the sample were maintained. Pore pressure was incrementally increased at a rate of 300 kPa every three minutes to simulate fluid injection. Temperature was raised rapidly and then stabilized for the duration of each test. The dataset includes shear stress and displacement measurements under each temperature condition, along with supplementary figures illustrating the experimental setup and time-series plots of pressures and temperature.

15 GEOTHERMAL ENERGY↗

NASA NTRS1987

Adhesion, friction, and deformation of ion-beam-deposited boron nitride films

The tribological properties and mechanical strength of boron nitride films were investigated. The BN films were predominantly amorphous and nonstoichiometric and contained small amounts of oxides and carbides. It was found that the yield pressure at full plasticity, the critical load to fracture, and the shear strength of interfacial adhesive bonds (considered as adhesion) depended on the type of metallic substrate on which the BN was deposited. The harder the substrate, the greater the critical load and the adhesion. The yield pressures of the BN film were 12 GPa for the 440C stainless steel substrate, 4.1 GPa for the 304 stainless steel substrate, and 3.3 GPa for the titanium substrate.

Miyoshi, Kazuhisa↗

NASA NTRS1987

Adhesion, friction and deformation of ion-beam-deposited boron nitride films

Miyoshi, K.↗

DOE OSTI2023

Assessment and Non-Destructive Evaluation of the Influence of Residual Solvent on a Two-Part Epoxy-Based Adhesive Using Ultrasonics

Polymers are increasingly being used in higher demanding applications due to their ability to tailor the properties of structures while allowing for a weight and cost reduction. Solvents play an important role in the manufacture of polymeric structures since they allow for a reduction in the polymer’s viscosity or assist with the dispersion of fillers into the polymer matrix. However, the incorrect removal of the solvent affects both the physical and chemical properties of polymeric materials. The presence of residual solvent can also negatively affect the curing kinetics and the final quality of polymers. Destructive testing is mainly performed to characterize the properties of these materials. However, this type of testing involves using lab-type equipment that cannot be taken in-field to perform in situ testing and requires a specific sample preparation. Here, a method is presented to non-destructively evaluate the curing process and final viscoelastic properties of polymeric materials using ultrasonics. In this study, changes in longitudinal sound speed were detected during the curing of an aerospace epoxy adhesive as a result of variations in polymer chemistry. To simulate the presence of residual solvent, samples containing different weight percentages of isopropyl alcohol were manufactured and tested using ultrasonics. Thermogravimetric analysis was used to show changes in the decomposition of the adhesive due to the presence of IPA within the polymer structure. Adding 2, 4, and 6 wt.% of IPA decreased the adhesive’s lap shear strength by 40, 58, and 71%, respectively. Ultrasonics were used to show how the solvent influenced the curing process and the final sound speed of the adhesive. Young’s modulus and Poisson’s ratio were determined using both the longitudinal and shear sound speeds of the adhesive. Using ultrasonics has the potential to non-invasively characterize the quality of polymers in both an in-field and manufacturing settings, ensuring their reliability during use in demanding applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1995

Fatigue Crack Growth and Crack Bridging in SCS-6/Ti-24-11

Interfacial damage induced by relative fiber/matrix sliding was found to occur in the bridged zone of unidirectional SCS-6/Ti-24Al-11Nb intermetallic matrix composite specimens subjected to fatigue crack growth conditions. The degree of interfacial damage was not uniform along the bridged crack wake. Higher damage zones were observed near the machined notch in comparison to the crack tip. The interfacial friction shear strength tau(sub f) measured in the crack wake using pushout testing revealed lower values than the as-received interface. Interfacial wear also reduced the strength of the bridging fibers. The reduction in fiber strength is thought to be a function of the magnitude of relative fiber/matrix displacements ind the degree of interfacial damage. Furthermore, two different fiber bridging models were used to predict the influence of bridging on the fatigue crack driving force. The shear lag model required a variable tau(sub f) in the crack wake (reflecting the degradation of the interface) before its predictions agreed with trends exhibited by the experimental data. The fiber pressure model did an excellent job in predicting both the FCG data and the DeltaCOD in the bridged zone even though it does not require a knowledge of tau(sub f).

Ghosn, Louis J.↗

NASA NTRS1976

Effect of polymer properties and adherend surfaces on adhesion

High temperature polymer surface characteristics associated with joint strength were evaluated. Selected samples represented composite adherends, aluminum filler and fiber glass carrier cloth. Detailed analysis of fractured joint surfaces revealed unique characteristics typical of the specific adhesive formulations and test conditions. A fracture mechanism model was developed for correlating macroscopic shear strength and microstructure of fracture surfaces. Applications were made to unpublished data on polyimides and fluoropolymers.

Dwight, D. W.↗

NASA NTRS2002

Flaw Tolerance in Lap Shear Brazed Joints

Vacuum brazing is a viable process to achieve strong permanent and hermetic joints in space. As in any joining process, brazed Joints have various imperfections and defects. It is important to understand the impact that flaws have on the load carrying capacity and performance of the brazed joints. This study focuses on the behavior of lap shear joints due to their engineering importance in brazed aerospace structures. In Part 1 an average shear strength capabilitY and failure modes of the single lap joints are explored. Specimens comprised of 0.090 inch thick 347 stainless steel sheet brazed with pure silver are tested in accordance with the AWS C3.2 standard. Comparison of the measured loads and average shear stresses at failure with the Finite Element Analysis (FEA) of the same specimens as a function of the overlap lengths shows excellent correlation between the experimental and calculated values for the defect-free lap joints. In Part 2, various flaws will be introduced in the test specimens to simulate lack of braze coverage in the lap joints. Mechanical testing and FEA will be performed on these joints to verify if behavior of ductile ]appoints containing flaws is similar to the joints with the reduced braze area. Finally, in Part 3, the results obtained in Part 1 and 2 will be applied to the brazed assembly to evaluate a load carrying capability of the structural lap joint containing defects.

Flom, Yury↗

NASA NTRS1982

Environmental exposure effects on composite materials for commercial aircraft

The effects of environmental exposure on composite materials are studied. The environments considered are representative of those experienced by commercial jet aircraft. Initial results have been compiled for the following material systems: T300/5208, T300/5209 and T300/934. Specimens were exposed on the exterior and interior of Boeing 737 airplanes of three airlines, and to continuous ground level exposure at four locations. In addition specimens were exposed in the laboratory to conditions such as: simulated ground-air-ground, weatherometer, and moisture. Residual strength results are presented for specimens exposed for up to two years at three ground level exposure locations and on airplanes from two airlines. Test results are also given for specimens exposed to the laboratory simulated environments. Test results indicate that short beam shear strength is sensitive to environmental exposure and dependent on the level of absorbed moisture.

Gibbins, M. N.↗

NASA NTRS1983

The effect of matrix properties and fiber properties on impact failure mechanics

The low-velocity impact problem in graphite/epoxy composite sheets must be solved before large amounts of that material can be used in commercial aircraft. Many of the low-velocity impacts that affect aircraft parts occur during normal ground operations and maintenance. Service equipment and tools have masses above 1 kg, and at velocities of less than 3 m/s can impact structural parts with energies higher than composites can endure without degradation of stiffness or strength. Simple solutions were developed for large-mass, low-velocity impacts which can be modeled as quasi-static events. Static test data and impact data show that the fiber properties control the impact energy which can be absorbed before penetration. Matrix shear strength and peel resistance control the extent of delamination. Comparison of results from tough matrix and brittle matrix composites show that although tough matrices reduce the extent of delamination, they lead to more fiber damage in the contact area.

Elber, W.↗

NASA NTRS1997

High Temperature Structural Foam

The Aerospace Industry is experiencing growing demand for high performance polymer foam. The X-33 program needs structural foam insulation capable of retaining its strength over a wide range of environmental conditions. The High Speed Research Program has a need for low density core splice and potting materials. This paper reviews the state of the art in foam materials and describes experimental work to fabricate low density, high shear strength foam which can withstand temperatures from -220 C to 220 C. Commercially available polymer foams exhibit a wide range of physical properties. Some with densities as low as 0.066 g/cc are capable of co-curing at temperatures as high as 182 C. Rohacell foams can be resin transfer molded at temperatures up to 180 C. They have moduli of elasticity of 0.19 MPa, tensile strengths of 3.7 Mpa and compressive strengths of 3.6 MPa. The Rohacell foams cannot withstand liquid hydrogen temperatures, however Imi-Tech markets Solimide (trademark) foams which withstand temperatures from -250 C to 200 C, but they do not have the required structural integrity. The research activity at NASA Langley Research Center focuses on using chemical blowing agents to produce polyimide thermoplastic foams capable of meeting the above performance requirements. The combination of blowing agents that decompose at the minimum melt viscosity temperature together with plasticizers to lower the viscosity has been used to produce foams by both extrusion and oven heating. The foams produced exhibit good environmental stability while maintaining structural properties.

Weiser, Erik S.↗

NASA NTRS1994

Failure analysis of woven and braided fabric reinforced composites

A general purpose micromechanics analysis that discretely models the yarn architecture within the textile repeating unit cell was developed to predict overall, three dimensional, thermal and mechanical properties, damage initiation and progression, and strength. This analytical technique was implemented in a user-friendly, personal computer-based, menu-driven code called Textile Composite Analysis for Design (TEXCAD). TEXCAD was used to analyze plain weave and 2x2, 2-D triaxial braided composites. The calculated tension, compression, and shear strengths correlated well with available test data for both woven and braided composites. Parametric studies were performed on both woven and braided architectures to investigate the effects of parameters such as yarn size, yarn spacing, yarn crimp, braid angle, and overall fiber volume fraction on the strength properties of the textile composite.

Naik, Rajiv A.↗

DOE OSTI2022

Effects of edge-seal design on the mechanical and thermal performance of vacuum-insulated glazing

Although vacuum-insulated glazing (VIG) has been proposed as a promising solution towards developing energy-efficient buildings, VIGs have not become popular in the market due to several technical challenges including the complexity of the fabrication process. In particular, the edge-seal is a key component that significantly affects the thermal insulation and mechanical performance, and the development of edge-seal with adequate thermal insulation, mechanical strength, and reasonable processing cost is essential to overcome such technical issues in VIG. For this purpose, effects of edge-seal design parameters on the VIG performance should be identified. In this research, we analyzed the edge-seal for thermal transport as well as structural stresses to study the effects, and then identified and evaluated the material mixes for the edge-seal requirements. Here, the finite element simulations showed the significance of VIG corner calculation on overall thermal transmittance and the importance of seal conductivity below 1 W/m.K. The experiments with the flexible seals with different ratios of fine glass powder demonstrated that the measured shear strength values for the seal with less than 30% glass powder were more than 10 times larger than the calculated shear stress values. Based on these simulation and experimental results, a flexible sealant was developed using a proprietary mix of ceramic materials that meets the requirements of the designed VIG edge-seal, including structural as well as thermal stress resistance and a low conductivity. Moreover, the sealant is self-curing under atmospheric conditions, and thus it does not require costly inline process of laser curing or oven baking.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

A generalized power-law criterion for rocks based on Mohr failure theory

Nonlinearity of Mohr envelopes confirmed by past laboratory test data can be of considerable importance in theoretical interpretation of rock strength behaviors and many practical applications. Current nonlinear failure criteria are introduced with parameters to empirically fit test data, and the physical and mechanical meanings of these fitting parameters are often not known. Predicted strengths by theoretical criteria (e.g., Griffith criterion) generally do not agree well with test data. Considering the nonlinear properties of a Mohr envelope, a nonlinear failure criterion in a generalized power-law form is derived in this paper based on strength magnitude coefficient (a) and failure envelope curvature coefficient (n) which are expressed in terms of uniaxial tensile strength, uniaxial compressive strength, and angle of internal friction. Test data on granite, marble, dolomite, and andesite from published literature were chosen to test the performance of the proposed criterion along with Griffith and Hoek-Brown criteria. Statistical analysis was performed to evaluate the application of different criteria in predicting the strength of rocks. In addition, some Griffith-typed criteria are mathematically shown to be the special cases of the proposed criterion. The proposed and Hoek-Brown criteria have similar power-law forms with a significant difference in the coefficient functions that govern the shear strength magnitude of rock. The different tensile and compressive failure mechanisms are also investigated from the perspective of the relationship between the uniaxial tension Mohr circle and the proposed failure envelope.

58 GEOSCIENCES↗