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The motivation for this work is to develop self-healing polymeric materials to enable damage tolerant systems, and to tailor puncture healing for use temperatures and applications. This will be a benefit in environments and conditions where access for manual repair is limited or impossible, or where damage may not be detected.
Although polyimide based composites have been used for many years in a wide variety of elevated temperature applications, very little work has been done to examine the durability and damage behavior under more prototypical thermomechanical fatigue (TMF) loadings. Synergistic effects resulting from simultaneous temperature and load cycling can potentially lead to enhanced, if not unique, damage modes and contribute to a number of nonlinear deformation responses. The goal of this research was to examine the effects of a TMF loading spectrum, representative of a gas turbine engine compressor application, on a polyimide sheet molding compound (SMC). High performance SMCs present alternatives to prepreg forms with great potential for low cost component production through less labor intensive, more easily automated manufacturing. To examine the issues involved with TMF, a detailed experimental investigation was conducted to characterize the durability of a T650-35/PMR-15 SMC subjected to TMF mission cycle loadings. Fatigue damage progression was tracked through macroscopic deformation and elastic stiffness. Additional properties, such as the glass transition temperature (T(sub g) and dynamic mechanical properties were examined. The fiber distribution orientation was also characterized through a detailed quantitative image analysis. Damage tolerance was quantified on the basis of residual static tensile properties after a prescribed number of TMF missions. Detailed microstructural examinations were conducted using optical and scanning electron microscopy to characterize the local damage. The imposed baseline TMF missions had only a modest impact on inducing fatigue damage with no statistically significant degradation occurring in the measured macroscopic properties. Microstructural damage was, however, observed subsequent to 100 h of TMF cycling which consisted primarily of fiber debonding and transverse cracking local to predominantly transverse fiber bundles. The TMF loadings did introduce creep related effects (strain accumulation) which led to rupture in some of the more aggressive stress scenarios examined. In some cases this creep behavior occurred at temperatures in excess of 150 C below commonly cited values for T(sub g). Thermomechanical exploratory creep tests revealed that the SMC was subject to time dependent deformation at stress/temperature thresholds of 150 MPa/230 C and 170 MPa/180 C.
Space exploration launch costs on the order of $10K per pound provide ample incentive to seek innovative, cost-effective ways to reduce structural mass without sacrificing safety and reliability. Damage-tolerant structural systems can provide a route to avoiding weight penalty while enhancing vehicle safety and reliability. Self-healing polymers capable of spontaneous puncture repair show great promise to mitigate potentially catastrophic damage from events such as micrometeoroid penetration. Effective self-repair requires these materials to heal instantaneously following projectile penetration while retaining structural integrity. Poly(ethylene-co-methacrylic acid) (EMMA), also known as Surlyn is an ionomer-based copolymer that undergoes puncture reversal (self-healing) following high impact puncture at high velocities. However EMMA is not a structural engineering polymer, and will not meet the demands of aerospace applications requiring self-healing engineering materials. Current efforts to identify candidate self-healing polymer materials for structural engineering systems are reported. Rheology, high speed thermography, and high speed video for self-healing semi-crystalline and amorphous polymers will be reported.
Damage development in woven SiC/SiNC ceramic matrix composites (CMC's) under tensile and cyclic loading both at room and elevated temperatures have been investigated for the exhaust nozzle of high-efficient turbine engines. The ultimate strength, failure strain, proportional limit and modulus data at a temperature range of 23 to 1250 C are generated. The tensile strength of SiC/SiNC woven composites have been observed to increase with increased temperatures up to 1000 C. The stress/strain plot shows a pseudo-yield point at 25 percent of the failure strain (epsilon(sub r)) which indicates damage initiation in the form of matrix cracking. The evolution of damage beyond 0.25 epsilon(sub f), both at room and elevated temperature comprises multiple matrix cracking, interfacial debonding, and fiber pullout. Although the nature of the stress/strain plot shows damage-tolerant behavior under static loading both at room and elevated temperature, the life expectancy of SiC/SiNC composites degrades significantly under cyclic loading at elevated temperature. This is mostly due to the interactions of fatigue damage caused by the mechanically induced plastic strain and the damage developed by the creep strain. The in situ damage evolutions are monitored by acoustic event parameters, ultrasonic C-scan and stiffness degradation. Rate equations for modulus degradation and fatigue life prediction of ceramic matrix composites both at room and elevated temperatures are developed. These rate equations are observed to show reasonable agreement with experimental results.
Delamination is one of the predominant forms of failure in laminated composites especially when there is no reinforcement in the thickness direction. To develop composite structures that are more damage tolerant, it is necessary to understand how delamination develops and how it can affect the residual performance. A number of factors such as residual thermal strains, matrix curing shrinkage, and manufacturing defects affect how damage will grow in a composite structure. It is important to develop analysis methods that are computationally efficient that can account for all such factors. The objective of the current work is to apply a newly developed decohesion element to investigate the debond strength of skin/stiffener composite specimens. The process of initiation of delaminations and the propagation of delamination fronts is investigated. The numerical predictions are compared with published experimental results.
In Spring of 2005, the NASA Engineering Safety Center (NESC) was engaged by the Space Shuttle Program (SSP) to peer review the suite of analytical tools being developed to support the determination of impact and damage tolerance of the Orbiter Thermal Protection Systems (TPS). The NESC formed an independent review team with the core disciplines of materials, flight sciences, structures, mechanical analysis and thermal analysis. The Math Model Tools reviewed included damage prediction and stress analysis, aeroheating analysis, and thermal analysis tools. Some tools are physics-based and other tools are empirically-derived. Each tool was created for a specific use and timeframe, including certification, real-time pre-launch assessments, and real-time on-orbit assessments. The tools are used together in an integrated strategy for assessing the ramifications of impact damage to tile and RCC. The NESC teams conducted a peer review of the engineering data package for each Math Model Tool. This report contains the summary of the team observations and recommendations from these reviews.
In Spring of 2005, the NASA Engineering Safety Center (NESC) was engaged by the Space Shuttle Program (SSP) to peer review the suite of analytical tools being developed to support the determination of impact and damage tolerance of the Orbiter Thermal Protection Systems (TPS). The NESC formed an independent review team with the core disciplines of materials, flight sciences, structures, mechanical analysis and thermal analysis. The Math Model Tools reviewed included damage prediction and stress analysis, aeroheating analysis, and thermal analysis tools. Some tools are physics-based and other tools are empirically-derived. Each tool was created for a specific use and timeframe, including certification, real-time pre-launch assessments. In addition, the tools are used together in an integrated strategy for assessing the ramifications of impact damage to tile and RCC. The NESC teams conducted a peer review of the engineering data package for each Math Model Tool. This report contains the summary of the team observations and recommendations from these reviews.
The integrity and reusability of three flight-weight metallic and RSI thermal protection systems, designed for the Shuttle entry environment, have been demonstrated. Each model successfully survived over 23 entry thermal cycles without serious degradation. The metallic systems were more tolerant of the hostile environment and provided a higher degree of reusability than did the RSI. Thermal expansion slip joints of the metallic TPS successfully prevented hot gas ingress to the substructure. The RSI demonstrated high damage tolerance and field repairs increased its reusability. Heat-transfer tests to further assess RSI gap heating indicate that stacked tile orientations may impose a penalty on tile thickness. Parameters influencing RSI impingement heating were determined, and the heating data were correlated.
Structural durability and damage tolerance characteristics of pressurized graphite/epoxy laminated thin composite cylinders are investigated via computational simulation. Both unstiffened and integral hoop stiffened cylinders are considered. A computer code is utilized for the simulation of composite structural degradation under loading. Damage initiation, growth, accumulation, and propagation to structural fracture are included in the simulation. The increase of burst pressure due to hoop stiffening is quantified. Results demonstrate the significance of the type and size of local defects on the structural durability of pressurized composite cylindrical shells.
The issue of damage tolerance after impact, in terms of the compressive residual strength, was experimentally examined in graphite/epoxy laminates using Hercules AS4/3501-6 in a (+ or - 45/0)(sub 2S) configuration. Three different impactor masses were used at various velocities and the resultant damage measured via a number of nondestructive and destructive techniques. Specimens were then tested to failure under uniaxial compression. The results clearly show that a minimum compressive residual strength exists which is below the open hole strength for a hole of the same diameter as the impactor. Increases in velocity beyond the point of minimum strength cause a difference in the damage produced and cause a resultant increase in the compressive residual strength which asymptotes to the open hole strength value. Furthermore, the results show that this minimum compressive residual strength value is independent of the impactor mass used and is only dependent upon the damage present in the impacted specimen which is the same for the three impactor mass cases. A full 3-D representation of the damage is obtained through the various techniques. Only this 3-D representation can properly characterize the damage state that causes the resultant residual strength. Assessment of the state-of-the-art in predictive analysis capabilities shows a need to further develop techniques based on the 3-D damage state that exists. In addition, the need for damage 'metrics' is clearly indicated.
Several structural sandwich composites arc in service on military and commercial aerospace vehicles, however, these components have been limited to secondary structures partly because the impact damage and damage tolerance of these composites have not been extensively characterized. To improve durability, safety, and life cycle performance of PMCs while reducing maintenance costs, combined analysis, and test methods that provide a means of predicting critical engineering properties after impact damage of the structure, must be developed. A key enabling technology here is the establishment of the correlation between the impact test results conducted in the laboratory and the mechanics-based phenomenological solutions. This research was undertaken to investigate the compression and flexural properties following low velocity impact of a nomex/phenolic honeycomb core, fiberglass/epoxy facesheet, midplane asymmetric sandwich composite. One facesheet (thin side) was composed of two plies of the fiberglass/epoxy (0/90), while the other facesheet (thick side) was composed of four plies (0/90/0/90) of fiberglass/epoxy. Due to the differences in facesheet thickness, impact damage was separately induced on the thick side as well as the thin side. The compression and flexural strength properties for each damage arrangement were compared using different levels of impact energy ranging from 0 to 452 Joules. In all cases, higher impact energy resulted in decreased compression and flexural strength. Impact on the thin side showed slightly more retention of compression strength at low impact levels, whereas higher residual compressive strength was observed from impact on the thick side at higher impact levels. Different facesheet thicknesses or midplane asymmetry, played an important role in the flexural strength, however, low velocity impact on the both the thick and thin fiberglass/epoxy facesheet side showed an almost linear loss of flexural strength to saturation.
Four fiber/resin systems were compared for resistance to damage and damage tolerance. One toughened epoxy and three toughened bismaleimide (BMI) resins were used., all with IM7 carbon fiber reinforcement. A statistical design of experiments technique was used to evaluate the effects of impact energy, specimen thickness and tup diameter on the damage area and residual compression-after-impact (CAI) strength. Results showed that two of the BMI systems sustained relatively large damage areas yet had an excellent retention of CAI strength.
Numerous design concepts, materials, and manufacturing methods were investigated for the covers and spars of a transport box wing. Cover panels and spar segments were fabricated and tested to verify the structural integrity of design concepts and fabrication techniques. Compression tests on stiffened panels demonstrated the ability of graphite/epoxy wing upper cover designs to achieve a 35 percent weight savings compared to the aluminum baseline. The impact damage tolerance of the designs and materials used for these panels limits the allowable compression strain and therefore the maximum achievable weight savings. Bending and shear tests on various spar designs verified an average weight savings of 37 percent compared to the aluminum baseline. Impact damage to spar webs did not significantly degrade structural performance. Predictions of spar web shear instability correlated well with measured performance. The structural integrity of spars manufactured by filament winding equalled or exceeded those fabricated by hand lay-up. The information obtained will be applied to the design, fabrication, and test of a full-scale section of a wing box. When completed, the tests on the technology integration box beam will demonstrate the structural integrity of an advanced composite wing design which is 25 percent lighter than the metal baseline.
This study investigated the effects of through-the-thickness stitching on impact damage resistance, impact damage tolerance, and mode I and mode II fracture toughness of textile graphite/epoxy laminates. Uniweave resin-transfer-molded 48 ply graphite/epoxy (AS4/3501-6) laminates were stitched with Kevlar and glass yarns of different linear densities and stitch spacings. Delaminations were implanted during processing to simulate impact damage. Sublaminate buckling tests were performed to determine the effects of stitching on the compressive strength. The results showed outstanding improvements of up to 400 percent in the compression strength over the unstitched laminates. In impact and static indentation tests the onset of damage occurred at the same level, but the extent of damage was less in stitched laminates. Mode I fracture toughness of 24 ply Uniweave unidirectional (AS4/3501-6) stitched laminates was measured by conducting double-cantilever-beam tests. The critical strain energy release rate (G(sub Ic)) was found to be up to 30 times higher than the unstitched laminates. Mode II fracture toughness of the Uniweave laminates was measured by performing end-notched-flexure tests. Two new methods to compute the apparent G(sub IIc) are presented. The apparent G(sub IIc) was found to be at least 5-15 times higher for the stitched laminates.
In support of recommendations by the Columbia Accident Investigation Board, a team has been studying the effect of debris impacting the reinforced carbon-carbon panels of the shuttle leading edge. The objective of this study was to examine the effect of varying parameters of the debris trajectory on the damage tolerance. Impacts at the upper and lower surface and the apex of the leading edge were examined. For each location, trajectory variances included both the alpha and beta directions. The results of the analysis indicated in all cases the beta sweep decreased the amount of damage to the panel. The increases in alpha resulted in a significant increase in damage to the RCC panel. In particular, for the lower surface, where the alpha can increase by 10 degrees, there was a nearly 40% increase in the impulse. As a result, it is recommended that for future analyses, a 10 degree offset in alpha from the nominal trajectory is included for impacts on the lower surface. It is also recommended to assume a straight aft, or zero beta, trajectory for a more conservative analysis.
Three dimensional (3D) woven composites have demonstrated multi-directional properties and improved transverse strength, impact resistance, and shear characteristics. The objective of this research is to develop a new model for predicting the elastic constants, hygrothermal effects, thermomechanical response, and stress limits of 3D woven composites; and to develop a computational tool to facilitate the evaluation of 3D woven composite structures with regard to damage tolerance and durability. Fiber orientations of weave and braid patterns are defined with reference to composite structural coordinates. Orthotropic ply properties and stress limits computed via micromechanics are transformed to composite structural coordinates and integrated to obtain the 3D properties. The various stages of degradation, from damage initiation to collapse of structures, in the 3D woven structures are simulated for the first time. Three dimensional woven composite specimens with various woven patterns under different loading conditions, such as tension, compression, bending, and shear are simulated in the validation process of this research. Damage initiation, growth, accumulation, and propagation to fracture are included in these simulations.
Stitched composite technology has the potential to substantially decrease structural weight through enhanced damage containment capabilities. The most recent generation of stitched composite technology, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, has been shown to successfully arrest damage at the sub-component level through tension testing of a three stringer panel with damage in the form of a two-bay notch. In a joint effort undertaken by the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and the Boeing Company, further studies are being conducted to characterize the damage containment features of the PRSEUS concept. A full-scale residual strength test will be performed on a fuselage panel to determine if the load capacity will meet strength, deformation, and damage tolerance requirements. A curved panel was designed, fabricated, and prepared for residual strength testing. A pre-test Finite Element Model (FEM) was developed using design allowables from previous test programs to predict test panel deformation characteristics and margins of safety. Three phases of testing with increasing damage severity include: (1) as manufactured; (2) barely visible impact damage (BVID) and visible impact damage (VID); and (3) discrete source damage (DSD) where the panel will be loaded to catastrophic failure. This paper presents the background information, test plan, and experimental procedure. This paper is the first of several future articles reporting the test preparations, results, and analysis conducted in the test program.
An experimental investigation was undertaken to quantify damage tolerance and resistance in composite materials impacted using the drop-weight method. Tests were conducted on laminates of several different carbon-fiber composite systems, such as epoxies, modified epoxies, and amorphous and semicrystalline thermoplastics. Impacted composite specimens were examined using destructive and non-destructive techniques to establish the characteristic damage states. Specifically, optical microscopy, ultrasonic, and scanning electron microscopy techniques were used to identify impact induced damage mechanisms. Damage propagation during post impact compression was also studied.