A Straightforward Approach to Thickness Tailoring in Composite Structures Using Non-traditional Layups
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Development of Stitched, Braided and Woven Composite Structures in the ACT Program and at Langley Research Center
Summary results are presented from the research conducted on woven, braided, knitted and stitched (textile) composites at the Langley Research Center and under the NASA Advanced Composites Technology (ACT) Program in the period from 1985 to 1997. The report also includes an annotated bibliography of 270 U.S. publications on textile composites (with their abstracts). Two major research areas are discussed: (1) the general research in textile composites performed throughout the period under the direction of the Langley Research Center and (2) the development of textile composite aircraft structures by industry under the NASA ACT Program. The annotated bibliography is organized in three subsections: (1) general textiles R&D under the auspices of Langley, (2) ACT Program development of textile structural components, and (3) textiles research by individuals and organizations not associated with the ACT Program. An author index is provided for the reports and documents.
Dow, Marvin B.↗
A sublaminate analysis method for predicting disbond and delamination loads in composite structures
A method is proposed for assessing the forces that can delaminate composite laminates and bonded structures. The approach employs a higher-order plate theory to represent portions of the laminate. The ply properties are integrated through the thickness in a manner that is consistent with the displacement assumptions in the plate theory, thus providing for accurate representation of the stacking sequence effects. In addition to stress analysis, the method also provides the strain energy release rate for the growth of existing delaminations. The analysis has been incorporated into a computer code, TTSS (through thickness stretching and shear). Application examples, including a double cantilever beam and a curved laminate, are examined.
Flanagan, G.↗
Optimum design of a composite structure with ply-interleaving constraints
The application of composite materials to aircraft construction has provided the designer with increased flexibility. The orientation of plies can be tailored to provide additional aeroelastic performance unobtainable with an isotropic material. A tailored laminate is made up of plies of several orientations, usually 0 deg, 45 deg, -45 deg, and 90 deg. The direction of the 0 deg plies, does not need to be oriented with the leading edge, but can be varied to obtain a wide variety of structural properties. Also, the number of plies of each orientation varies from one zone to another on the planform. Thus, a thick laminate with mainly 0 deg plies may form the root zone, and a thinner laminate with mainly +45 deg plies may form the leading edge zone. Tailored laminates were designed using complicated optimization programs. Unfortunately, many tailored designs must be modified before they are manufactured. The modification adds weight and decreases performance. One type of modification is ply interleaving, an overlap of plies between zones on the laminate. These interleaves are added to ensure that zones with varying ply percentages can be connected without loss of strength. In this paper, the constraints needed to eliminate interleaves in the laminate optimization process will be described and implemented in a structural optimization problem. The method used has the potential to prevent changes to composite laminates late in the design cycle.
Wang, Bo Ping↗
Composite structural materials
A decade long program to develop critical advanced composite technology in the areas of physical properties, structural concept and analysis, manufacturing, reliability, and life predictions is reviewed. Specific goals are discussed. The status of the chemical vapor deposition effects on carbon fiber properties; inelastic deformation of metal matrix laminates; fatigue damage in fibrous MMC laminates; delamination fracture toughness in thermoplastic matrix composites; and numerical analysis of composite micromechanical behavior are presented.
Loewy, Robert G.↗
Composite structures for commercial transport aircraft
The use of composites represents one of six possible approaches which, according to a NASA program initiated in 1975, could be used collectively to reduce the fuel consumption of commercial transport aircraft by up to 50 percent. A description is provided of a NASA-industry program which will lead to a more extensive use of advanced composites. The approach being taken is to develop, for existing aircraft, components which have potential for significant weight savings. The design of each of the considered components is described, taking into account a graphite/epoxy rudder, an inboard aileron, a graphite-epoxy elevator, a vertical tail, a horizontal tail, and a vertical stabilizer. The components are in various stages of development at this time. Preliminary weight estimates show from 25 to 30 percent weight savings from the use of composites.
Vosteen, L. F.↗
Composite structural materials
Transverse properties of fiber constituents in composites, fatigue in composite materials, matrix dominated properties of high performance composites, numerical investigation of moisture effects, numerical investigation of the micromechanics of composite fracture, advanced analysis methods, compact lug design, and the RP-1 and RP-2 sailplanes projects are discussed.
Ansell, G. S.↗
The interiors of Pluto and Charon - Structure, composition, and implications
Recent models of the internal structure of Pluto and Charon, made possible by analysis of the Pluto/Charon mutual events are reviewed. At a mean density of just over 2 g/cu cm and a predicted rock mass fraction of roughly 0.7, the Pluto/Charon system is significantly rockier than the icy satellites of the giant planets, a contrast which may reflect its formation in a CO-rich outer solar nebula rather than a circumplanetary nebula. Pluto and Charon may in fact be so rocky that they lost volatiles early in their history (possibly during a Charon-forming impact event), although this is still an open issue.
Simonelli, Damon P.↗
Composite structure global fracture toughness via computational simulation
A computational method for the simulation of damage and fracture propagation in laminated composites is presented. A quantitative evaluation of the global fracture toughness of composites is shown as a tool for monitoring the fracture stability of composites under sustained loading. Changes in overall structural properties such as natural frequencies and the fundamental buckling load are also computed with increasing load-induced damage. Structural degradation, delamination, fracture, and damage propagation are included in the simulation. An angle-plied composite plate structure subjected to inplane tensile loading is used as an example to demonstrate some of the feature of the computational method.
Minnetyan, L.↗
Composite structural armor for combat vehicle applications
Several projects that have demonstrated the advantages of using thick composite armor technology for structural applications in armored combat vehicles are discussed. The first involved composite cargo doors for the Marine Corps LVTP-7 amphibious landing vehicle. Another was a demonstration composite turret that offered a weight reduction of 15.5 percent. The advantages of this composite armor compared to metallic armors used for combat vehicle hull and turret applications are reduced weight at equal ballistic protection; reduced back armor spall; excellent corrosion resistance; reduced production costs by parts consolidation; and inherent thermal and acoustic insulative properties. Based on the encouraging results of these past programs, the Demonstration Composite Hull Program was started in September 1986. To demonstrate this composite armor technology, the Army's newest infantry fighting vehicle, the Bradley Fighting Vehicle (BFV), was selected as a model. A composite infantry fighting vehicle, designated the CIFV for this program, has been designed and fabricated and is currently undergoing a 6000 mile field endurance test. The CIFV demonstration vehicle uses the BFV engine, transmission, suspension, track and other equipment.
Haskell, William E., III↗
Reliability and life prediction of ceramic composite structures at elevated temperatures
Methods are highlighted that ascertain the structural reliability of components fabricated of composites with ceramic matrices reinforced with ceramic fibers or whiskers and subject to quasi-static load conditions at elevated temperatures. Each method focuses on a particular composite microstructure: whisker-toughened ceramics, laminated ceramic matrix composites, and fabric reinforced ceramic matrix composites. In addition, since elevated service temperatures usually involve time-dependent effects, a section dealing with reliability degradation as a function of load history has been included. A recurring theme throughout this chapter is that even though component failure is controlled by a sequence of many microfailure events, failure of ceramic composites will be modeled using macrovariables.
Duffy, Stephen F.↗
Probabilistic nonlinear finite element analysis of composite structures
A probabilistic finite element analysis procedure for laminated composite shells is developed. A total Lagrangian finite element formulation, employing a degenerated three-dimensional laminated composite shell element with the full Green-Lagrange strains and first-order shear deformable kinematics, is used. The first-order second-moment technique for probabilistic finite element analysis of random fields is employed, and results are presented in the form of mean and variance of the structural response. Reliability calculations are made by using the first-order reliability method combined with sensitivity derivatives from the finite element analysis. Both ply-level and micromechanics-level random variables are incorporated, the latter by means of the Aboudi micromechanics model. Two sample problems are solved to verify the accuracy of the procedures developed and to quantify the variability of certain material type/structure combinations. In general, the procedure is quite effective in determining the response statistics and reliability for linear and geometric nonlinear behavior of laminated composite shells.
Engelstad, S. P.↗
Composite Structures Materials Testing for the Orion Crew Vehicle Heat Shield
As research is being performed for the new heat shield for the Orion capsule, National Aeronautics and Space Administration (NASA) is developing the first composite heat shield. As an intern of the Structures Branch in the Engineering Directorate (ES 2), my main task was to set up a test plan to determine the material properties of the honeycomb that will be used on the Orion Crew Module heat shield to verify that the composite is suitable for the capsule. Before conducting composite shell tests, which are performed to simulate the crush performance of the heat shield on the capsule, it is necessary to determine the compression and shear properties of the composite used on the shell. During this internship, I was responsible for developing a test plan, designing parts for the test fixtures as well as getting them fabricated for the honeycomb shear and compression testing. This involved work in Pro/Engineer as well as coordinating with Fab Express, the Building 9 Composite Shop and the Structures Test Laboratory (STL). The research and work executed for this project will be used for composite sandwich panel testing in the future as well. As a part of the Structures Branch, my main focus was to research composite structures. This involves system engineering and integration (SE&I) integration, manufacturing, and preliminary testing. The procedures for these projects that were executed during this internship included design work, conducting tests and performing analysis.
Khemani, Farah N.↗
Ground test experience with large composite structures for commercial transports
The initial ground test of each component resulted in structural failure at less than ultimate design loads. While such failures represent major program delays, the investigation and analysis of each failure revealed significant lessons for effective utilization of composites in primary structure. Foremost among these are secondary loads that produce through-the-thickness forces which may lead to serious weaknesses in an otherwise sound structural design. The sources, magnitude, and effects of secondary loads need to be thoroughly understood and accounted for by the designers of composite primary aircraft structures.
Bohon, H. L.↗
Ground test experience with large composite structures for commercial transports
The initial ground test of each component resulted in structural failure at less than ultimate design loads. While such failures represent major program delays, the investigation and analysis of each failure revealed significant lessons for effective utilization of composites in primary structure. Foremost among these are secondary loads that produce through-the-thickness forces which may lead to serious weaknesses in an otherwise sound structural design. The sources, magnitude, and effects of secondary loads need to be thoroughly understood and accounted for by the designers of composite primary aircraft structures.
Bohon, H. L.↗
Fiber composite structural durability and damage tolerance: Simplified predictive methods
Simplified predictive methods and models (theory) to evaluate fiber/polymer-matrix composite material for determining structural durability and damage tolerance are presented and described. This theory includes equations for (1) fatigue and fracture of composites without and with defects, (2) impact resistance and residual strength after impact, (3) thermal fatigue, and (4) combined stress fatigue. Several examples are included to illustrate applications of the theory and to identify significant parameters and sensitivities. Comparisons with limited experimental data are made.
Chamis, Christos C.↗
Fiber composite structural durability and damage tolerance - Simplified predictive methods
Simplified predictive methods and models (theory) to evaluate fiber/polymer-matrix composite material for determining structural durability and damage tolerance are presented and described. This theory includes equations for (1) fatigue and fracture of composites without and with defects, (2) impact resistance and residual strength after impact, (3) thermal fatigue, and (4) combined stress fatigue. Several examples are included to illustrate applications of the theory and to identify significant parameters and sensitivities. Comparisons with limited experimental data are made.
Chamis, Christos C.↗
Effect of service environments on adhesively bonded joints in composite structures
The models employed in the present computational methods for evaluating severe service-environment effects on adhesively bonded joints in composites are based on composite analyses and structural mechanics, encompassing nonlinear environmental degradation. The methods are demonstrated for the case of a butt joint with a single doubler, subjected to the environmental effects as well as static and cyclic loads. The highest joint strength is noted to be required in the case of cyclic loads and hygrothermal service environments; margins of safety for adhesive material stresses decline rapidly in such cases.
Singhal, S. N.↗