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All sources NASA NTRS DOE OSTI

NASA NTRS1991

Structural characterization of high temperature composites

Glass, ceramic, and carbon matrix composite materials have emerged in recent years with potential properties and temperature resistance which make them attractive for high temperature applications such as gas turbine engines. At the outset of this study, only flexural tests were available to evaluate brittle matrix composites at temperatures in the 600 to 1000 C range. The results are described of an ongoing effort to develop appropriate tensile, compression, and shear test methods for high temperature use. A tensile test for unidirectional composites was developed and used to evaluate the properties and behavior of ceramic fiber reinforced glass and glass-ceramic matrix composites in air at temperatures up to 1000 C. The results indicate generally efficient fiber reinforcement and tolerance to matrix cracking similar to polymer matrix composites. Limiting properties in these materials may be an inherently very low transverse strain to failure, and high temperature embrittlement due to fiber/matrix interface oxidation.

Mandell, J. F.↗

NASA NTRS2001

NASA Software of the Year, GENOAPFA, Given 2000 R and D 100 Award

GENOA-PFA, marketed currently by Alpha Star Corporation, is an enhanced commercial version of the Composite Durability Structural Analysis (CODSTRAN) computer program that was originally developed in-house at NASA Glenn Research Center specifically for polymer-matrix composite structures. Alpha Star Corporation and the University of Clarkson ha ve made substantial developments to the code under the NASA Small Bus iness Innovation Research and University Grant support. The code won the NASA Software of the year award in 1999 and was given the 2000 R&D 100 Award. The current GENOA-PFA can simulate the initiation and pro gression of damage, ultimately leading to global fracture in advanced composite structures under various loading and environmental conditi ons. It offers a number of capabilities beyond those of programs developed previously for similar purposes; these capabilities make GENOA-P FA preferable for use in analyzing the durability and damage toleranc e of complex aero and space structures that have fiber reinforcements formed as two- and even three-dimensional weaves and braids.

Murthy, Pappu L. N.↗

NASA NTRS2010

Modeling of Failure for Analysis of Triaxial Braided Carbon Fiber Composites

In the development of advanced aircraft-engine fan cases and containment systems, composite materials are beginning to be used due to their low weight and high strength. The design of these structures must include the capability of withstanding impact loads from a released fan blade. Relatively complex triaxially braided fiber architectures have been found to yield the best performance for the fan cases. To properly work with and design these structures, robust analytical tools are required that can be used in the design process. A new analytical approach models triaxially braided carbon fiber composite materials within the environment of a transient dynamic finite-element code, specifically the commercially available transient dynamic finite-element code LS-DYNA. The geometry of the braided composites is approximated by a series of parallel laminated composites. The composite is modeled by using shell finite elements. The material property data are computed by examining test data from static tests on braided composites, where optical strain measurement techniques are used to examine the local strain variations within the material. These local strain data from the braided composite tests are used along with a judicious application of composite micromechanics- based methods to compute the stiffness properties of an equivalent unidirectional laminated composite required for the shell elements. The local strain data from the braided composite tests are also applied to back out strength and failure properties of the equivalent unidirectional composite. The properties utilized are geared towards the application of a continuum damage mechanics-based composite constitutive model available within LS-DYNA. The developed model can be applied to conduct impact simulations of structures composed of triaxially braided composites. The advantage of this technology is that it facilitates the analysis of the deformation and damage response of a triaxially braided polymer matrix composite within the environment of a transient dynamic finite-element code such as LS-DYNA in a manner which accounts for the local physical mechanisms but is still computationally efficient. This methodology is tightly coupled to experimental tests on the braided composite, which ensures that the material properties have physical significance. Aerospace or automotive companies interested in using triaxially braided composites in their structures, particularly for impact or crash applications, would find the technology useful. By the development of improved design tools, the amount of very expensive impact testing that will need to be performed can be significantly reduced.

Goldberg, Robert K.↗

NASA NTRS1990

NASA's HITEMP program for UHBR engines

NASA's High Temperature Engine Materials Program (HITEMP) is concerned with the laboratory-scale technology development and feasibility demonstration of high-temperature composite materials, in conjunction with the requisite structural analysis models and test methods for their validation. HITEMP encompasses research on metallic/intermetallic, ceramic, and polymer matrix composites, and is giving attention to high-temperature component composites applicable to future widebody commercial aircraft ultrahigh bypass ratio (UHBR) engines. The UHBR components for which advanced composites are envisioned are fan, compressor, and turbine rotor blades, stator vanes, disks, and shafts, thrust bearings, gearbox bearings and linings, combustor cases and linings, nacelles, and thrust-reversers.

Stephens, Joseph R.↗

NASA NTRS1995

Standard methods for open hole tension testing of textile composites

Sizing effects have been investigated by comparing the open hole failure strengths of each of the four different braided architectures as a function of specimen thickness, hole diameter, and the ratio of specimen width to hole diameter. The data used to make these comparisons was primarily generated by Boeing. Direct comparisons of Boeing's results were made with experiments conducted at West Virginia University whenever possible. Indirect comparisons were made with test results for other 2-D braids and 3-D weaves tested by Boeing and Lockheed. In general, failure strength was found to decrease with increasing plate thickness, increase with decreasing hole size, and decreasing with decreasing width to diameter ratio. The interpretation of the sensitive to each of these geometrical parameters was complicated by scatter in the test data. For open hole tension testing of textile composites, the use of standard testing practices employed by industry, such as ASTM D5766 - Standard Test Method for Open Hole Tensile Strength of Polymer Matrix Composite Laminates should provide adequate results for material comparisons studies.

Portanova, M. A.↗

NASA NTRS1983

A proposed approach to the application of nonlinear irreversible thermodynamics to fracture in composite materials

The fracture criteria upon which most fracture mechanics is based involves an energy balance that is not appropriate for the fracture mechanics of viscoelastic materials such as polymer matrix composites. A more appropriate criterion based upon nonequilibrium thermodynamics and involving a power balance rather than an energy balance is proposed. This crierion is based upon a reformulation of the second law of thermodynamics which focuses attention on the total Legendre transform of energy expressed as a functional over time and space. This excess energy functional can be shown to be equivalent to the Rice J integral if the only irreversible process is the propogation of a single crack completely through the thickness of the specimen and if the crack propogation is assured to be independent of time. For the more general case of more than one crack in a viscoelastic medium integration over both time and space is required. Two experimentally measurable parameters are proposed which should permit the evaluation of this more general fracture criterion.

Lindenmeyer, P. H.↗

NASA NTRS1982

Space environmental effects on materials

Research efforts at NASA-Langley to characterize the durability of composite materials which are candidates for use as components on various space hardware systems are reviewed. The material applications include large space structures, antennas, cables, thermal control coatings, solar reflectors, and satellite power systems. Simulation facilities have been built to study radiation effects on polymer matrix composites, and the dimensional stability of the matrix composites and tension stabilized cables. Numerical models are being developed for radiation effects on the mechanical, physical, and optical properties. Additionally, chemical and microstructural analyses are performed to identify damage mechanisms and the limits of effectiveness of accelerating life tests. It is noted that no residual strength reduction has been detected in polymer films after dosages of 5 billion rads of electron radiation.

Tenney, D. R.↗

NASA NTRS1991

Effects of elevated temperature on the viscoplastic modeling of graphite/polymeric composites

To support the development of new materials for the design of next generation supersonic transports, a research program is underway at NASA to assess the long term durability of advanced polymer matrix composites (PMC's). One of main objectives of the program was to explore the effects of elevated temperature (23 to 200 C) on the constitutive model's material parameters. To achieve this goal, test data on the observed nonlinear, stress-strain behavior of IM7/5260 and IM7/8320 composites under tension and compression loading were collected and correlated against temperature. These tests, conducted under isothermal conditions using variable strain rates, included such phenomena as stress relaxation and short term creep. The second major goal was the verification of the model by comparison of analytical predictions and test results for off axis and angle ply laminates. Correlation between test and predicted behavior was performed for specimens of both material systems over a range of temperatures. Results indicated that the model provided reasonable predictions of material behavior in load or strain controlled tests. Periods of loading, unloading, stress relaxation, and creep were accounted for.

Gates, Thomas S.↗

NASA NTRS2001

Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structure

This viewgraph presentation gives an assessment of the state-of-the-art in the design and manufacturing of large component structures, including details on the use of continuous fiber reinforced polymer matrix composites (CFRP) in commercial and military aircraft and in space launch vehicles. Project risk mitigation plans must include a building-block test approach to structural design development, manufacturing process scale-up development tests, and pre-flight ground tests to verify structural integrity. The potential benefits of composite structures justifies NASA's investment in developing the technology. Advanced composite structures technology is enabling to virtually every Aero-Space Technology Enterprise Goal.

Harris, C. E.↗

NASA NTRS1999

Probabilistic Assessment of Fracture Progression in Composite Structures

This report describes methods and corresponding computer codes that are used to evaluate progressive damage and fracture and to perform probabilistic assessment in built-up composite structures. Structural response is assessed probabilistically, during progressive fracture. The effects of design variable uncertainties on structural fracture progression are quantified. The fast probability integrator (FPI) is used to assess the response scatter in the composite structure at damage initiation. The sensitivity of the damage response to design variables is computed. The methods are general purpose and are applicable to stitched and unstitched composites in all types of structures and fracture processes starting from damage initiation to unstable propagation and to global structure collapse. The methods are demonstrated for a polymer matrix composite stiffened panel subjected to pressure. The results indicated that composite constituent properties, fabrication parameters, and respective uncertainties have a significant effect on structural durability and reliability. Design implications with regard to damage progression, damage tolerance, and reliability of composite structures are examined.

Chamis, Christos C.↗

NASA NTRS2002

PMR-15/Layered Silicate Nanocomposites For Improved Thermal Stability And Mechanical Properties

Montmorillonite clay was organically modified by co-exchange of an aromatic diamine and a primary alkyl amine. The clay was dispersed into a PMR (Polymerization of Monomer Reactants)-15 matrix and the glass transition temperature and thermal oxidative stability of the resulting nanocomposites were evaluated. PMR-15/ silicate nanocomposites were also investigated as a matrix material for carbon fabric reinforced composites. Dispersion of the organically modified silicate into the PMR-15 matrix enhanced the thermal oxidative stability, the flexural strength, flexural modulus, and interlaminar shear strength of the polymer matrix composite.

Campbell, Sandi↗

DOE OSTI2021

Enhancing functionalities in carbon fiber composites by titanium dioxide nanoparticles

Carbon fiber composite's high specific strength makes it incredibly useful for structural applications. However, their low strain-to-failure can be problematic in structural applications that can potentially see high strain conditions or high fatigue cycles resulting in sudden, catastrophic failure. This is further complicated by damage manifesting within the composite thus not showing damage indicators on the surface. Therefore, monitoring the structural integrity and strain history of the composite in application by itself—while maintaining positive composite performance—is vital to ensure safe operation. In this study, a homogeneous dispersion of TiO 2 nanoparticles on carbon fiber is demonstrated to generate a piezoresistive carbon fiber polymer matrix composite with enhanced self-sensing capabilities. The nanoparticle-embedded composites also exhibited superior strength and damping potential compared to the nanoparticle-free composites. The apparent interlaminar shear strength increased by up to 15% and the damping loss factor increased by an average of 150% while the piezoresistive sensitivity increased by up to 180% with the addition of a small weight fraction of nanoparticles to the fiber surface. These results demonstrate an approach to simultaneously improve the sensing capabilities, damping behavior and mechanical strength of carbon fiber composites by simply adding nanoparticles in the fiber sizing using a commercially scalable deposition method.

36 MATERIALS SCIENCE↗

NASA NTRS2016

Additive Manufacturing of Silicon Carbide-Based Ceramic Matrix Composites: Technical Challenges and Opportunities

Advanced SiC-based ceramic matrix composites offer significant contributions toward reducing fuel burn and emissions by enabling high overall pressure ratio (OPR) of gas turbine engines and reducing or eliminating cooling air in the hot-section components, such as shrouds, combustor liners, vanes, and blades. Additive manufacturing (AM), which allows high value, custom designed parts layer by layer, has been demonstrated for metals and polymer matrix composites. However, there has been limited activity on additive manufacturing of ceramic matrix composites (CMCs). In this presentation, laminated object manufacturing (LOM), binder jet process, and 3-D printing approaches for developing ceramic composite materials are presented. For the laminated object manufacturing (LOM), fiber prepreg laminates were cut into shape with a laser and stacked to form the desired part followed by high temperature heat treatments. For the binder jet, processing optimization was pursued through silicon carbide powder blending, infiltration with and without SiC nano powder loading, and integration of fibers into the powder bed. Scanning electron microscopy was conducted along with XRD, TGA, and mechanical testing. Various technical challenges and opportunities for additive manufacturing of ceramics and CMCs will be presented.

ceramic matrix composites↗

NASA NTRS2024

Pull-off Behavior of Stitched Composite T-Joints

T-joints are key structural elements that connect opposing surfaces, thereby providing the load path between flat or curved panels (i.e., upper and lower wing skins) and transverse components (i.e., stiffeners). Due to the low interlaminar strength of polymer matrix composites and their geometrical discontinuities, these joints are vulnerable to pull-off loads. To address these issues, through-thickness reinforcements can be employed to enhance the interlaminar capability of these type of joints. In this study, T-joints were manufactured using through-thickness stitching in dry carbon preforms and cured using the vacuum-assisted resin transfer molding (VARTM) process. Stitched and unstitched T-joints were tested under pull-off loading conditions, and surface strain fields were obtained using a 3D digital image correlation system. The ultimate load, displacement, and absorbed energy of the stitched T-joints were greater than their unstitched counterparts by approximately 16%, 34%, and 58%, respectively. Failure mechanisms were identified by examining fracture surfaces using optical microscopy. Results demonstrate that through-thickness stitching significantly improves the damage tolerance of T-joints, which highlights the effectiveness of stitching to enhance the structural integrity of large aerospace components.

VARTM↗

NASA NTRS1992

Computational simulation of surface waviness in graphite/epoxy woven composites due to initial curing

Several models simulating plain weave, graphite/epoxy woven composites are presented, along with the effects that the simultaneous application of pressure and thermal loads have on their surfaces. The surface effects created by moisture absorption are also examined. The computational simulation consisted of using a two-dimensional finite element model for the composite. The properties of the finite element (FE) model are calculated by using the in-house composite mechanics computer code ICAN (Integrated Composite ANalyzer). MSC/NASTRAN is used for the FE analysis which yields the composite's top surface normalized displacements. These results demonstrate the importance of parameters such as the cure temperature (T sub o) and the resin content in the curing process of polymer-matrix composites. The modification of these parameters will help tailor the composite system to the desired requirements and applications.

Sanfeliz, Jose G.↗

NASA NTRS1992

Computational simulation of surface waviness in graphite/epoxy woven composites due to initial curing

Sanfeliz, Jose G.↗

NASA NTRS2012

Structural Analysis and Optimization of a Composite Fan Blade for Future Aircraft Engine

This report addresses the structural analysis and optimization of a composite fan blade sized for a large aircraft engine. An existing baseline solid metallic fan blade was used as a starting point to develop a hybrid honeycomb sandwich construction with a polymer matrix composite face sheet and honeycomb aluminum core replacing the original baseline solid metallic fan model made of titanium. The focus of this work is to design the sandwich composite blade with the optimum number of plies for the face sheet that will withstand the combined pressure and centrifugal loads while the constraints are satisfied and the baseline aerodynamic and geometric parameters are maintained. To satisfy the requirements, a sandwich construction for the blade is proposed with composite face sheets and a weak core made of honeycomb aluminum material. For aerodynamic considerations, the thickness of the core is optimized whereas the overall blade thickness is held fixed so as to not alter the original airfoil geometry. Weight is taken as the objective function to be minimized by varying the core thickness of the blade within specified upper and lower bounds. Constraints are imposed on radial displacement limitations and ply failure strength. From the optimum design, the minimum number of plies, which will not fail, is back-calculated. The ply lay-up of the blade is adjusted from the calculated number of plies and final structural analysis is performed. Analyses were carried out by utilizing the OpenMDAO Framework, developed at NASA Glenn Research Center combining optimization with structural assessment.

Coroneos, Rula M.↗

NASA NTRS1989

Space radiation effects on dimensional stability of composites

The long-term space environment at GEO, consisting of high doses (less than 10 to the 9th rads) of electron radiation and large cyclic (-157 C to +121 C) temperature changes, can significantly affect the dimensional stability of polymer matrix composites. Radiation alters the chemical structure of epoxies by both chain scission and cross-linking. In this paper, an attempt is made to summarize and examine the effects of electron radiation damage on dimensional stability of composites. Microcracking measurements were made for standard 177 C cure Gr/Ep, rubber toughened Gr/Ep, Gr/Polymide, and GR/Thermoplastic composites. Results show that radiation damage can significantly change matrix-dependent mechanical and physical properties of composites, with data explaining how these changes can affect their dimensional stability.

Tenney, Darrel R.↗