Mechanisms of strengthening and fracture in composite materials Third progress report, 1 Jun. - 30 Nov. 1965
Mechanism of strengthening and fracture in composite materials - tensile strength, impact deformation, brittleness,
DEFORMATION↗
SEARCH · Search NASA
Results for “brittle materials”
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.
A B-spline based gradient-enhanced micropolar implicit material point method for large localized inelastic deformations
The quasi-brittle response of cohesive-frictional materials in numerical simulations is commonly represented by softening plasticity or continuum damage models, either individually or in combination. However, classical models, particularly when coupled with non-associated plasticity, often suffer from ill-posedness and a lack of objectivity in numerical simulations. Moreover, the performance of the finite element method significantly degrades in simulations involving finite strains when mesh distortion reaches excessive levels. This represents a challenge for modeling cohesive-frictional materials, given their tendency to experience strongly localized deformations, such as those occurring during shear band dominated failure. Hence, accurate modeling of the response of cohesive-frictional solids is a demanding task. To address these challenges, we present an extension of the material point method (MPM) for the unified gradient-enhanced micropolar continuum, aiming at the analysis of finite localized inelastic deformations in cohesive-frictional materials. The generalized gradient-enhanced micropolar continuum formulation is employed to tackle challenges related to localization and softening material behavior, while the MPM addresses issues arising from excessive deformations. The method utilizes a B-spline formulation for the rigid background mesh to mitigate the well-known cell crossing errors of the MPM. To demonstrate the performance of the method, 2D and 3D numerical studies on localized failure in sandstone in plane strain compression and triaxial extension tests are presented. A comparison with finite element results confirms the suitability of the formulation. Moreover, an efficient numerical implementation of the formulation is presented, and it is demonstrated that the additional MPM specific overhead is negligible.
B-spline↗
Isocyanate Cross-Linked Silica: Structurally Strong Aerogels
Molecular-level synergism between the silica nanoparticles of pre-formed monoliths and molecular cross-linkers inverts the relative host-guest roles in glass-polymer composites, leading to new strong low-density materials. Attempts to load gels with variable amounts of polyurethane precursors such as di-ISO and diol end-capped polybutylene adipate followed by heat treatment, washing, and supercritical drying led to opaque materials, somewhat stronger than silica but still quite brittle and much inferior to the materials described above. Direct mixing of a diisocyanate and an alcohol-free sol has been attempted recently by Yim et al. Reportedly, that procedure leads to week-long gelation times and requires an at least equally long aging period. In our attempt to add various amounts of di-ISO in a base-catalyzed sol in PC, we also noticed a week-long gelation time. The resulting aerogels were translucent but no less brittle than native silica. According to more recent studies, if propylene carbonate is replaced with acetone, it leads not only to shorter processing times, but also to much stronger gels that can tolerate loads in excess of 40 kg in the arrangement presented. We attribute that behavior to the lower viscosity of acetone, that allows faster diffusion of the di-ISO solution within the pores before di-ISO has time to react with the surface of silica. Further studies are underway to vary the chemical identity of the diisocyanate, as well as the composition and density of silica.
Leventis, Nicholas↗
Impact response of composite materials
Composite materials composed of carbon fibers and resin matrices offer great promise in reducing the weight of aerospace structures. However they remain extremely vulnerable to out of plane impact loads, which lead to severe losses in strength and stiffness. The results of an experimental program, undertaken to investigate the low velocity impact damage tolerance of composite materials is presented. The objectives were to identify key neat resin/composite properties that lead to enhancement of composite impact damage tolerance and to find a small scale test that predicts compression after impact properties of panels. Five materials were selected for evaluation. These systems represented different classes of material behavior such as brittle epoxy, modified epoxies, and amorphous and semicrystalling thermoplastics. The influence of fiber properties on the impact performance was also studied in one material, i.e., in polyether ether ketone (PEEK). Several 24 and 48 ply quasi-isotropic and 24 ply orthotropic laminates were examined using an instrumented drop weight impactor. Correlations with post impact compression behavior were made.
Tiwari, S. N.↗
Analysis of the progressive failure of brittle matrix composites
This report investigates two of the most common modes of localized failures, namely, periodic fiber-bridged matrix cracks and transverse matrix cracks. A modification of Daniels' bundle theory is combined with Weibull's weakest link theory to model the statistical distribution of the periodic matrix cracking strength for an individual layer. Results of the model predictions are compared with experimental data from the open literature. Extensions to the model are made to account for possible imperfections within the layer (i.e., nonuniform fiber lengths, irregular crack spacing, and degraded in-situ fiber properties), and the results of these studies are presented. A generalized shear-lag analysis is derived which is capable of modeling the development of transverse matrix cracks in material systems having a general multilayer configuration and under states of full in-plane load. A method for computing the effective elastic properties for the damaged layer at the global level is detailed based upon the solution for the effects of the damage at the local level. This methodology is general in nature and is therefore also applicable to (0(sub m)/90(sub n))(sub s) systems. The characteristic stress-strain response for more general cases is shown to be qualitatively correct (experimental data is not available for a quantitative evaluation), and the damage evolution is recorded in terms of the matrix crack density as a function of the applied strain. Probabilistic effects are introduced to account for the statistical nature of the material strengths, thus allowing cumulative distribution curves for the probability of failure to be generated for each of the example laminates. Additionally, Oh and Finney's classic work on fracture location in brittle materials is extended and combined with the shear-lag analysis. The result is an analytical form for predicting the probability density function for the location of the next transverse crack occurrence within a crack bounded region. The results of this study verified qualitatively the validity of assuming a uniform crack spacing (as was done in the shear-lag model).
Thomas, David J.↗
Fabrication of Lanthanum Telluride 14-1-11 Zintl High-Temperature Thermoelectric Couple
The development of more efficient thermoelectric couple technology capable of operating with high-grade heat sources up to 1,275 K is key to improving the performance of radioisotope thermoelectric generators. Lanthanum telluride La3-xTe4 and 14-1-11 Zintls (Yb14MnSb11) have been identified as very promising materials. The fabrication of advanced high-temperature thermoelectric couples requires the joining of several dissimilar materials, typically including a number of diffusion bonding and brazing steps, to achieve a device capable of operating at elevated temperatures across a large temperature differential (up to 900 K). A thermoelectric couple typically comprises a heat collector/ exchanger, metallic interconnects on both hot and cold sides, n-type and ptype conductivity thermoelectric elements, and cold-side hardware to connect to the cold-side heat rejection and provide electrical connections. Differences in the physical, mechanical, and chemical properties of the materials that make up the thermoelectric couple, especially differences in the coefficients of thermal expansion (CTE), result in undesirable interfacial stresses that can lead to mechanical failure of the device. The problem is further complicated by the fact that the thermoelectric materials under consideration have large CTE values, are brittle, and cracks can propagate through them with minimal resistance. The inherent challenge of bonding brittle, high-thermal-expansion thermoelectric materials to a hot shoe material that is thick enough to carry the requisite electrical current was overcome. A critical advantage over prior art is that this device was constructed using all diffusion bonds and a minimum number of assembly steps. The fabrication process and the materials used are described in the following steps: (1) Applying a thin refractory metal foil to both sides of lanthanum telluride. To fabricate the n-type leg of the advanced thermoelectric couple, the pre-synthesized lanthanum telluride coupon was diffusion bonded to the metal foil using a thin adhesion layer. (2) Repeating a similar process for the 14-1-11 Zintl p-type leg of the advanced thermoelectric couple. (3) Bonding thick CTE-matched metal plates on the metallized lanthanum telluride and Yb14MnSb11 to form the hot and cold sides of the thermoelectric couple. The calculated conversion efficiency of such an advanced couple would be about 10.5 percent, about 35 percent better than heritage radioisotope thermoelectric technology that relies on Si-Ge alloys. In addition, unlike Si-Ge alloys, these materials can be combined with many other thermoelectric materials optimized for operation at lower temperatures to achieve conversion efficiency in excess of 15 percent (a factor of 2 increase over heritage technology).
Ravi, Vilupanur A.↗
A Dual Approach in Direct Ink Writing of Thermally Cured Shape Memory Rubber Toughened Epoxy
Bisphenol A-based epoxies are much used in a wide range of composite and coating applications due to their excellent thermomechanical properties. However, their 3D printability remains a challenge with most reported materials suffering from high brittleness and low toughness. In this work, we have described especially modified epoxy resins that enable 3D printing with both fast and slow curing rates. These materials exhibit greatly enhanced toughness, tunable thermomechanical properties, and excellent shape memory behavior. Two different printing systems, including a two-part static mixing printhead and a single extrusion printhead, were developed for fast- and slow-curing epoxies, respectively. The rheology of inks in both systems has been modified into printable thixotropic fluids with the aid of silica nanoparticles and other additives. Epoxide-functionalized telechelic polybutadiene was added into the resins, which are then introduced inside the epoxy network after cross-linking. The addition of polybutadiene rubber significantly improves the toughness (over 135%), fracture strain (over 200%), and shape memory behavior. By adding different amounts of the rubber telechelic, thermomechanical properties, including modulus, elongation, and Tg of epoxy, can be well controlled in a wide range to satisfy different applications.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Tensile and fatigue characterization of multifunctional composites
This research is part of a larger effort to develop advanced self-sensing multifunctional polymer composites that are both lightweight and high-strength, while also enabling structural damage detection, fatigue cycle monitoring, and service life prediction. These multifunctional composites are particularly sought after in the automotive industry for their potential to significantly reduce vehicle weight and simultaneously provide additional functionality like condition monitoring to enhance safety. This study examines the tensile and fatigue properties of a composite material composed of acrylonitrile butadiene styrene (ABS) polymer embedded with piezoelectric barium titanate (BaTiO3) nanoparticles. The integration of BaTiO3 nanoparticles not only supplies the material with self-sensing capabilities but also influences its mechanical properties. While a high content of BaTiO3 nanoparticles is desired to enhance sensing capacity, the brittle nature of such materials causes concerns of decreased strength characteristics. To explore this, various composite samples were fabricated with nanoparticle contents ranging from 0 wt% to 20 wt%. These samples underwent tensile testing to measure their ultimate tensile strengths and Young’s moduli. Following this, fatigue tests were conducted to generate S-N curves, which are essential for understanding the material's durability under cyclic loading. The findings from these tests assess the impact of nanoparticle content on the composite’s tensile strength and fatigue life, providing essential insights that can guide the optimization and design of future self-sensing multifunctional composites. The results suggest that 5 wt% BaTiO3 provides an optimal balance between mechanical properties and nanoparticle concentration, making it a promising composition for semi-structural applications.
Bowland, Christopher [ORNL] (ORCID:000000021229431↗
Challenges and Prospects of All-Solid-State Electrodes for Solid-State Lithium Batteries
In the development of all-solid-state lithium batteries (ASSLB), progress is made with solid-state electrolytes; however, challenges regarding compatibility and stability still exist with solid electrodes. These issues result in a low battery capacity and short cycle life, which limit the commercial application of ASSLBs. Here, this review summarizes the recent research progress on solid-state electrodes in ASSLBs including the solid–solid interface phenomena such as the interface between electrode materials and electrolytes. The mechanical stability problems in solid electrodes, including fracture, brittleness, and deformation of electrode materials, are also discussed, and corresponding methods to measure the solid electrode stress are provided. In addition, strategies for mitigating stress-related issues are examined. Finally, the fabrication process of solid electrodes is introduced and their future developments, including the exploration of new electrode materials and the design of more intelligent electrode structures, are proposed.
25 ENERGY STORAGE↗
Loading rate sensitivity of open hole composites in compression
The results are reported of an experimental study on the compressive, time-dependent behavior of graphite fiber reinforced polymer composite laminates with open holes. The effect of loading rate on compressive strength was determined for six material systems ranging from brittle epoxies to thermoplastics at both 75 F and 220 F. Specimens were loaded to failure using different loading rates. The slope of the strength versus elapsed time-to-failure curve was used to rank the materials' loading rate sensitivity. All of the materials had greater strength at 75 F than at 220 F. All the materials showed loading rate effects in the form of reduced failure strength for longer elapsed-time-to-failure. Loading rate sensitivity was less at 220 F than the same material at 70 F. However, C12000/ULTEM and IM7/8551-7 were more sensitive to loading rate than the other materials at 220 F. AS4/APC2 laminates with 24, 32, and 48 plies and 1/16 and 1/4 inch diameter holes were tested. The sensitivity to loading rate was less for either increasing number of plies or larger hole size. The failure of the specimens made from brittle resins was accompanied by extensive delaminations while the failure of the roughened systems was predominantly by shear crippling. Fewer delamination failures were observed at the higher temperature.
Lubowinski, Steve J.↗
Loading rate sensitivity of open-hole composite specimens in compression
The results are reported of an experimental study on the compressive, time-dependent behavior of graphite fiber reinforced polymer composite laminates with open holes. The effect of loading rate on compressive strength was determined for six material systems ranging from brittle epoxies to thermoplastics at both 75 F and 220 F. Specimens were loaded to failure using different loading rates. The slope of the strength versus elapsed time-to-failure curve was used to rank the materials' loading rate sensitivity. All of the materials had greater strength at 75 F than at 220 F. All the materials showed loading rate effects in the form of reduced failure strength for longer elapsed-time-to-failure. Loading rate sensitivity was less at 220 F than the same material at 70 F. However, C12000/ULTEM and IM7/8551-7 were more sensitive to loading rate than the other materials at 220 F. AS4/APC2 laminates with 24, 32, and 48 plies and 1/16 and 1/4 inch diameter holes were tested. The sensitivity to loading rate was less for either increasing number of plies or larger hole size. The failure of the specimens made from brittle resins was accompanied by extensive delaminations while the failure of the roughened systems was predominantly by shear crippling. Fewer delamination failures were observed at the higher temperature.
Lubowinski, S. J.↗
An additive manufacturing design approach to achieving high strength and ductility in traditionally brittle alloys via laser powder bed fusion
Additive Manufacturing (AM) presents unprecedented opportunities to enable design freedom in parts that are unachievable via conventional manufacturing. However, AM-processed components generally lack the necessary performance metrics for widespread commercial adoption. We present a novel AM processing and design approach using removable heat sink artifacts to tailor the mechanical properties of traditionally low strength and low ductility alloys. The design approach is demonstrated with the Fe-50 at.% Co alloy, as a model material of interest for electromagnetic applications. AM-processed components exhibited unprecedented performance, with a 300 % increase in strength and an order-of-magnitude improvement in ductility relative to conventional wrought material. These results are discussed in the context of product performance, production yield, and manufacturing implications toward enabling the design and processing of high-performance, next-generation components, and alloys.
36 MATERIALS SCIENCE↗
Analyses of Buckling and Stable Tearing in Thin-Sheet Materials
This paper was to verify the STAGS (general shell, geometric and material nonlinear) code and the critical crack tip opening angle (CTOA) fracture criterion for predicting stable tearing in cracked panels that fail with severe out of plane buckling. Materials considered ranged from brittle to ductile behavior. Test data used in this study are reported elsewhere. The STAGS code was used to model stable tearing using a critical CTOA value that was determined from a cracked panel that was 'restrained' from buckling. ne analysis methodology was then used to predict the influence of buckling on stable tearing and failure loads. Parameters like crack length to specimen width ratio, crack configuration, thickness, and material tensile properties had a significant influence on the buckling behavior of cracked thin sheet materials. Experimental and predicted results showed a varied buckling response for different crack length to sheet thickness ratios because different buckling modes were activated. Effects of material tensile properties and fracture toughness on buckling response were presented. The STAGS code and the CTOA fracture criterion were able to predict the influence of buckling on stable tearing behavior and failure loads on a variety of materials and crack configurations.
Seshadri, B. R.↗
Fracture of PC and PMMA cylinders in the Taylor tests
The present paper analyzes failure observed in polymer rods collided with a steel anvil under the Taylor cylinder impact experiments. The experimental and numerical analysis demonstrates that association of the failure patterns with the loading mode depends on the rod material. Two materials are considered in the paper, specifically, polymethylmethacrylate (PMMA) and polycarbonate (PC). Damage in PMMA rods at the Taylor tests is shown to be dominated by the shear load resulting in plastic deformation. In contrast, the major mechanism of damage in PC rods is governed by omni-directional (pressure) mode of load. Analysis of the damage in sections of the rods associated with the glass transition is also addressed in the present theoretical study. Failure in these polymers follows the traditional fracture wave mechanism for brittle glass-type materials due to load in the corresponding mode. Numerical analysis employs a two-phase model with improved inter-phase thermal balance accounting for the inter-phase mass, momentum, and heat exchanges during the glass phase transition, while damage being accumulated in time. In conclusion, the simulation results demonstrate a good correlation with the experimental results.
36 MATERIALS SCIENCE↗
Temperature and radiation effects on brittle versus ductile fracture behavior in miscible phase boundaries: insight from atomistic simulations
Temperature- and irradiation-assisted failure mechanisms in miscible phase boundaries are clarified via atomistic calculations. We first establish the temperature-dependent brittle-to-ductile transition in U–Zr miscible phase boundaries. Our results confirm that these boundaries are mostly brittle at low temperatures and ductile at elevated temperatures. We then investigate the changes induced by irradiation on the fracture mechanisms in such phase boundaries. The irradiation-induced defect accumulation follows a multi-stage process that starts with the accumulation of isolated small dislocation loops before transitioning to the saturation and growth of larger dislocation loops and end up with a reorganization into forest dislocations. The accumulation of loops is the primary feature to participate in the delineation between brittle and ductile interfacial fracture in irradiated phase boundaries. At low damage levels, radiation defect interactions with the crack tip are limited and U–Zr miscible boundaries fail through the emission of dislocations ahead of the crack tip followed by brittle cleavage in agreement with the classical Griffith’s criterion for crack stability. At higher damage levels, the failure mode transitions from brittle crack growth to ductile void growth. In this case, the microcrack tip is blunted by the high density of pre-existing, radiation-induced defects in the vicinity of the crack. This interaction leads to the development and growth of a cavity at the interface as opposed to interfacial cleavage.
36 MATERIALS SCIENCE↗
Toughening Brittle Bio‐P3HB with Synthetic P3HB of Engineered Stereomicrostructures
Abstract Poly(3‐hydroxybutyrate) (P3HB), a biologically produced, biodegradable natural polyester, exhibits excellent thermal and barrier properties but suffers from mechanical brittleness, largely limiting its applications. Here we report a mono‐material product design strategy to toughen stereoperfect, brittle bio or synthetic P3HB by blending it with stereomicrostructurally engineered P3HB. Through tacticity ([ mm ] from 0 to 100 %) and molecular weight ( M n to 788 kDa) tuning, high‐performance synthetic P3HB materials with tensile strength to ≈30 MPa, fracture strain to ≈800 %, and toughness to 126 MJ m −3 (>110× tougher than bio‐P3HB) have been produced. Physical blending of the brittle P3HB with such P3HB in 10 to 90 wt % dramatically enhances its ductility from ≈5 % to 95–450 % and optical clarity from 19 % to 85 % visible light transmittance while maintaining desirably high elastic modulus (>1 GPa), tensile strength (>35 MPa), and melting temperature (160–170 °C). This P3HB‐toughening‐P3HB methodology departs from the traditional approach of incorporating chemically distinct components to toughen P3HB, which hinders chemical or mechanical recycling, highlighting the potential of the mono‐material product design solely based on biodegradable P3HB to deliver P3HB materials with diverse performance properties.
Zhang, Zhen↗
Toughening Brittle Bio‐P3HB with Synthetic P3HB of Engineered Stereomicrostructures
Abstract Poly(3‐hydroxybutyrate) (P3HB), a biologically produced, biodegradable natural polyester, exhibits excellent thermal and barrier properties but suffers from mechanical brittleness, largely limiting its applications. Here we report a mono‐material product design strategy to toughen stereoperfect, brittle bio or synthetic P3HB by blending it with stereomicrostructurally engineered P3HB. Through tacticity ([ mm ] from 0 to 100 %) and molecular weight ( M n to 788 kDa) tuning, high‐performance synthetic P3HB materials with tensile strength to ≈30 MPa, fracture strain to ≈800 %, and toughness to 126 MJ m −3 (>110× tougher than bio‐P3HB) have been produced. Physical blending of the brittle P3HB with such P3HB in 10 to 90 wt % dramatically enhances its ductility from ≈5 % to 95–450 % and optical clarity from 19 % to 85 % visible light transmittance while maintaining desirably high elastic modulus (>1 GPa), tensile strength (>35 MPa), and melting temperature (160–170 °C). This P3HB‐toughening‐P3HB methodology departs from the traditional approach of incorporating chemically distinct components to toughen P3HB, which hinders chemical or mechanical recycling, highlighting the potential of the mono‐material product design solely based on biodegradable P3HB to deliver P3HB materials with diverse performance properties.
Chemistry↗
Mechanical Properties of Irradiated U-10wt%Mo Alloy Degraded by Porosity Development
A plate-type nuclear fuel consisting of a solid monolithic foil of U-10wt%Mo is under development for use in the United States’ high performance research reactors. In support of developing this fuel, the fuel has been fabricated for the first time by a commercial fuel vendor and subsequently irradiated in a test reactor. This provides an opportunity to evaluate post-irradiation mechanical properties of commercially fabricated fuel. Four-point bend testing was conducted on the irradiated U-10Mo fuel and the data produced includes bending strength and Young’s modulus. Although the material behaves in a brittle manner due to the developed porosity, a general trend of strength and modulus reduction are found as fission density increases. The data produced is evaluated using both Weibull statistics and a modulus degradation model with recommendations provided.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗