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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

Experimental investigations into composite fuselage impact damage resistance and post-impact compression behavior

Impact damage resistance and residual strength of laminated composite transport aircraft fuselage structure was studied experimentally. Techniques to quantify impact damage discretely and non-discretely are described. Experimental techniques to three-dimensionally map matrix damage and determine the sublaminate structure are illustrated. Impact damage was also quantified non-discretely, using characteristics of flexural wave propagation. Strain distributions in compressively loaded impact damaged laminates were experimentally measured.

Dost, E. F.↗
NASA NTRS1992

Damage and failure mechanisms of continuous glass fiber reinforced polyphenylene sulfide

The damage that accompanies flexural deformation of a unidirectional glass fiber composite of polyphenylene sulfide was examined by AE and SEM. These complementary techniques were used to identify damage mechanisms at the microscale and correlate them with the macroscopic stress state in four-point bending. The flexural stress-strain curve was nominally linear to about 1.0 percent strain, but the onset of damage detectable by AE occurred at 0.3 percent strain. Two peaks in the AE amplitude distribution were observed at 35 dB and 60 dB. Low-amplitude events were detected along the entire length of the specimen, and correlation with direct observations of damage made by deforming the composite on the SEM stage suggested that these events arose from matrix cracking and fiber debonding concentrated at flaws on the composite. High amplitude events occurred primarily in the region of highest flexural stress between the inner loading points. They were attributed to fracture of glass fibers on the tension side and surface damage on the compressive side.

Chen, F.↗
NASA NTRS1993

On the enhancement of impact damage tolerance of composite laminates

This paper examines the use of a thin layer of Ultra High Molecular Weight Polyethylene (UHMWPE) on the outer surface of carbon/epoxy composite materials as a method of improving impact resistance and damage tolerance through hybridization. Flat 16-ply laminates as well as honeycomb sandwich structures with eight-ply facesheets were tested in this study. Instrumented drop-weight impact testing was used to inflict damage upon the specimens. Evaluation of damage resistance included instrumented impact data, visual examination, C-scanning and compression after impact (CAI) testing. The results show that only one lamina of UHMWPE did not improve the damage tolerance (strength retention) of the 16-ply flat laminate specimens or the honeycomb sandwich beams, however, a modest gain in impact resistance (detectable damage) was found for the honeycomb sandwich specimens that contained an outer layer of UHMWPE.

Nettles, A. T.↗
NASA NTRS1993

BLASIM - A computational tool to assess ice impact damage on engine blades

A portable computer code called BLASIM is developed at NASA LeRC to assess the ice impact damage on aircraft engine blades. In addition to the ice impact analyses, the code is also capable of carrying out static, dynamic, resonance margin and flutter analyses. The blade can be solid, hollow, superhybrid or composite material. An optional preprocessor (input generator) is also developed to generate input to the code through interactive process. The blade geometry can be defined either by a series of airfoils at discrete input stations or by a finite element grid. The code employs a coarse fixed finite element mesh with triangular plate finite elements and has quick turnaround time. The ice piece is modeled as an equivalent spherical object and has the velocity opposite to that of the aircraft with direction parallel to the engine axis. For the local impact damage assessment, the impact force is considered as a distributed load acting over a region around the impact point and the average radial strain of the finite elements along the leading edge is taken as a measure of the local damage. To estimate the damage at the blade root, the impact is considered to be an impulse and a combined stress failure criteria is employed. Parametric studies for local and root ice impact damage, and post-impact dynamics are discussed for solid and composite blades.

Reddy, E. S.↗
NASA NTRS1993

A numerical model for predicting crack path and modes of damage in unidirectional metal matrix composites

A finite element-based numerical technique has been developed to simulate damage growth in unidirectional composites. This technique incorporates elastic-plastic analysis, micromechanics analysis, failure criteria, and a node splitting and node force relaxation algorithm to create crack surfaces. Any combination of fiber and matrix properties can be used. One of the salient features of this technique is that damage growth can be simulated without pre-specifying a crack path. In addition, multiple damage mechanisms in the forms of matrix cracking, fiber breakage, fiber-matrix debonding and plastic deformation are capable of occurring simultaneously. The prevailing failure mechanism and the damage (crack) growth direction are dictated by the instantaneous near-tip stress and strain fields. Once the failure mechanism and crack direction are determined, the crack is advanced via the node splitting and node force relaxation algorithm. Simulations of the damage growth process in center-slit boron/aluminum and silicon carbide/titanium unidirectional specimens were performed. The simulation results agreed quite well with the experimental observations.

Bakuckas, J. G.↗
NASA NTRS1993

Compression of laminated composite beams with initial damage

The effect of isolated damage modes on the compressive strength and failure characteristics of laminated composite test specimens were evaluated experimentally and numerically. In addition to specimens without initial damage, specimens with three types of initial damage were considered: (1) specimens with short delaminations distributed evenly through the specimen thickness, (2) specimens with few long delaminations, and (3) specimens with local fiber damage in the surface plies under the three-point bend contact point. It was found that specimens with short multiple delamination experienced the greatest reduction in compression strength compared to the undamaged specimens. Single delaminations far from the specimen surface had little effect on the final compression strength, and moderate strength reduction was observed for specimens with localized surface ply damage.

Breivik, Nicole L.↗
NASA NTRS1993

Delamination, durability, and damage tolerance of laminated composite materials

Durability and damage tolerance may have different connotations to people from different industries and with different backgrounds. Damage tolerance always refers to a safety of flight issue where the structure must be able to sustain design limit loads in the presence of damage and return to base safely. Durability, on the other hand, is an economic issue where the structure must be able to survive a certain life under load before the initiation of observable damage. Delamination is typically the observable damage mechanism that is of concern for durability, and the growth and accumulation of delaminations through the laminate thickness is often the sequence of events that leads to failure and the loss of structural integrity.

Obrien, T. Kevin↗
NASA NTRS1993

Demonstrating damage tolerance of composite airframes

Commercial transport aircraft operating in the United States are certified by the Federal Aviation Authority to be damage tolerant. On 28 April 1988, Aloha Airlines Flight 243, a Boeing 727-200 airplane, suffered an explosive decompression of the fuselage but landed safely. This event provides very strong justification for the damage tolerant design criteria. The likely cause of the explosive decompression was the linkup of numerous small fatigue cracks that initiated at adjacent fastener holes in the lap splice joint at the side of the body. Actually, the design should have limited the damage size to less than two frame spacings (about 40 inches), but this type of 'multi-site damage' was not originally taken into account. This cracking pattern developed only in the high-time airplanes (many flights). After discovery in the fleet, a stringent inspection program using eddy current techniques was inaugurated to discover these cracks before they linked up. Because of concerns about safety and the maintenance burden, the lap-splice joints of these high-time airplanes are being modified to remove cracks and prevent new cracking; newer designs account for 'multi-site damage'.

Poe, Clarence C., Jr.↗
NASA NTRS1994

A coupled/uncoupled deformation and fatigue damage algorithm utilizing the finite element method

A fatigue damage computational algorithm utilizing a multiaxial, isothermal, continuum based fatigue damage model for unidirectional metal matrix composites has been implemented into the commercial finite element code MARC using MARC user subroutines. Damage is introduced into the finite element solution through the concept of effective stress which fully couples the fatigue damage calculations with the finite element deformation solution. An axisymmetric stress analysis was performed on a circumferentially reinforced ring, wherein both the matrix cladding and the composite core were assumed to behave elastic-perfectly plastic. The composite core behavior was represented using Hill's anisotropic continuum based plasticity model, and similarly, the matrix cladding was represented by an isotropic plasticity model. Results are presented in the form of S-N curves and damage distribution plots.

Wilt, Thomas E.↗
NASA NTRS1994

Damage and strength of composite materials: Trends, predictions, and challenges

Research on damage mechanisms and ultimate strength of composite materials relevant to scaling issues will be addressed in this viewgraph presentation. The use of fracture mechanics and Weibull statistics to predict scaling effects for the onset of isolated damage mechanisms will be highlighted. The ability of simple fracture mechanics models to predict trends that are useful in parametric or preliminary designs studies will be reviewed. The limitations of these simple models for complex loading conditions will also be noted. The difficulty in developing generic criteria for the growth of these mechanisms needed in progressive damage models to predict strength will be addressed. A specific example for a problem where failure is a direct consequence of progressive delamination will be explored. A damage threshold/fail-safety concept for addressing composite damage tolerance will be discussed.

Obrien, T. Kevin↗
NASA NTRS1994

Scaling of impact damage in fiber composites

Impact damage in fiber composite structures remains of much concern, and is often the limiting factor in establishing allowable strain levels. The complexity of impact damage formation usually dictates that experiments are required, but scaling of results from small laboratory scale specimens to large structures introduces additional uncertainty into the analysis. This presentation gives the results of an analytical and experimental investigation intended to develop procedures for prediction of damage formation and subsequent strength loss, with particular emphasis on scaling of results with respect to structure size. The experimental investigation involved both drop-weight and airgun impact on carbon/epoxy plates and cylinders. Five sizes of plates ranging from 50 by 50 by 1.072 mm to 250 by 250 by 5.36 mm, and two sizes of cylinders with diameters of 96.5 and 319 mm, were employed in the experimental program. Impact tests were carried out over a range of impact conditions, and specimens were inspected for damage by C-scan and deplying. Analysis procedures were developed for both quasistatic and dynamic impacts for both the plates and cylinders. As has been reported previously, comparison of predicted structural response and measured surface strains was quite good over the entire range of sizes employed in the program. The damage formation and strength loss after impact showed a number of interesting features that are significant with respect to scaling of size. The extent of delamination was observed to increase with specimen size more than would be expected if stresses controlled the delamination extent. This was explained on the basis that delamination is controlled by energy release rates, and thus incorporates the usual dependence on the absolute size characteristic of fracture mechanics. Additionally, the experiments indicated that delamination initiated at matrix cracks and is dependent on the absolute size of the ply group thicknesses. Both the initiation and propagation of delamination are seen to be controlled by fracture mechanics parameters, and thus show specific dependence on size that must be accounted for in extrapolating results from laboratory scale tests to full size structures.

Swanson, Stephen R.↗
NASA NTRS1994

Fatigue analysis of multiple site damage at a row of holes in a wide panel

This paper is concerned with predicting the fatigue life of unstiffened panels which contain multiple site damage (MSD). The initial damage consists of through-the-thickness cracks emanating from a row of holes in the center of a finite width panel. A fracture mechanics analysis has been developed to predict the growth, interaction, and coalescence of the various cracks which propagate in the panel. A strain-life analysis incorporating Neuber's rule for notches, and Miner's rule for cumulative damage, is also employed to predict crack initiation for holes without initial cracking. This analysis is compared with the results of a series of fatigue tests on 2024-T3 aluminum panels, and is shown to do an excellent job of predicting the influence of MSD on the fatigue life of nine inch wide specimens. Having established confidence in the ability to analyze the influence of MSD on fatigue life, a parametric study is conducted to examine the influence of various MSD scenarios in an unstiffened panel. The numerical study considered 135 cases in all, with the parametric variables being the applied cyclic stress level, the lead crack geometry, and the number and location of MSD cracks. The numerical analysis provides details for the manner in which lead cracks and MSD cracks grow and coalesce leading to final failure. The results indicate that MSD located adjacent to lead cracks is the most damaging configuration, while for cases without lead cracks, MSD clusters which are not separated by uncracked holes are most damaging.

Buhler, Kimberley↗
NASA NTRS1992

Application of damage tolerance methodology in certification of the Piaggio P-180 Avanti

The Piaggio P-180 Avanti, a twin pusher-prop engine nine-passenger business aircraft was certified in 1990, to the requirements of FAR Part 23 and Associated Special Conditions for Composite Structure. Certification included the application of a damage tolerant methodology to the design of the composite forward wing and empennage (vertical fin, horizontal stabilizer, tailcone, and rudder) structure. This methodology included an extensive analytical evaluation coupled with sub-component and full-scale testing of the structure. The work from the Damage Tolerance Analysis Assessment was incorporated into the full-scale testing. Damage representing hazards such as dropped tools, ground equipment, handling, and runway debris, was applied to the test articles. Additional substantiation included allowing manufacturing discrepancies to exist unrepaired on the full-scale articles and simulated bondline failures in critical elements. The importance of full-scale testing in the critical environmental conditions and the application of critical damage are addressed. The implication of damage tolerance on static and fatigue testing is discussed. Good correlation between finite element solutions and experimental test data was observed.

Johnson, Jerry↗
NASA NTRS1992

Applications of a damage tolerance analysis methodology in aircraft design and production

Objectives of customer mandated aircraft structural integrity initiatives in design are to guide material selection, to incorporate fracture resistant concepts in the design, to utilize damage tolerance based allowables and planned inspection procedures necessary to enhance the safety and reliability of manned flight vehicles. However, validated fracture analysis tools for composite structures are needed to accomplish these objectives in a timely and economical manner. This paper briefly describes the development, validation, and application of a damage tolerance methodology for composite airframe structures. A closed-form analysis code, entitled SUBLAM was developed to predict the critical biaxial strain state necessary to cause sublaminate buckling-induced delamination extension in an impact damaged composite laminate. An embedded elliptical delamination separating a thin sublaminate from a thick parent laminate is modelled. Predicted failure strains were correlated against a variety of experimental data that included results from compression after impact coupon and element tests. An integrated analysis package was developed to predict damage tolerance based margin-of-safety (MS) using NASTRAN generated loads and element information. Damage tolerance aspects of new concepts are quickly and cost-effectively determined without the need for excessive testing.

Woodward, M. R.↗
NASA NTRS1993

The combined effect of glass buffer strips and stitching on the damage tolerance of composites

Recent research has demonstrated that through-the-thickness stitching provides major improvements in the damage tolerance of composite laminates loaded in compression. However, the brittle nature of polymer matrix composites makes them susceptible to damage propagation, requiring special material applications and designs to limit damage growth. Glass buffer strips, embedded within laminates, have shown the potential for improving the damage tolerance of unstitched composite laminates loaded in tension. The glass buffer strips, less stiff than the surrounding carbon fibers, arrest crack growth in composites under tensile loads. The present study investigates the damage tolerance characteristics of laminates that contain both stitching and glass buffer strips.

Kullerd, Susan M.↗
NASA NTRS1992

Nondestructive monitoring damage in composites using scanning laser acoustic microscopy

Several Nicalon fiber reinforced LAS (lithium alumino-silicate) glass matrix composites were tested to study the relation between the residual strength and the different amounts of damage. The samples were fatigued by four-point cyclic loading at a 5 Hz rate at 500 C for a different number of cycles. 10 MHz scanning laser acoustic microscope (SLAM) images were taken to monitor damage on the samples. Our SLAM results indicate that there were defects already existing throughout the sample before fatigue, and the resultant damage pattern from fatigue could be related to the initial defect distribution in the sample. Finally, the fatigued samples were fractured and the residual strength data could not be explained by the cyclic fatigue alone. Rather, the damage patterns evident in the SLAM images were needed to explain the scatter in the data. The results show that SLAM is useful in nondestructively monitoring damage and estimating residual strength of fatigued ceramic composites.

Wey, A. C.↗
NASA NTRS1995

Real time acousto-ultrasonic NDE technique for monitoring damage in ceramic composites under dynamic loads

Research effort was directed towards developing a near real-time, acousto-ultrasonic (AU), nondestructive evaluation (NDE) tool to study the failure mechanisms of ceramic composites. Progression of damage is monitored in real-time by observing the changes in the received AU signal during the actual test. During the real-time AU test, the AU signals are generated and received by the AU transducers attached to the specimen while it is being subjected to increasing quasi-static loads or cyclic loads (10 Hz, R = 1.0). The received AU signals for 64 successive pulses were gated in the time domain (T = 40.96 micro sec) and then averaged every second over ten load cycles and stored in a computer file during fatigue tests. These averaged gated signals are representative of the damage state of the specimen at that point of its fatigue life. This is also the first major attempt in the development and application of real-time AU for continuously monitoring damage accumulation during fatigue without interrupting the test. The present work has verified the capability of the AU technique to assess the damage state in silicon carbide/calcium aluminosilicate (SiC/CAS) and silicon carbide/ magnesium aluminosilicate (SiC/MAS) ceramic composites. Continuous monitoring of damage initiation and progression under quasi-static ramp loading in tension to failure of unidirectional and cross-ply SiC/CAS and quasi-isotropic SiC/MAS ceramic composite specimens at room temperature was accomplished using near real-time AU parameters. The AU technique was shown to be able to detect the stress levels for the onset and saturation of matrix cracks, respectively. The critical cracking stress level is used as a design stress for brittle matrix composites operating at elevated temperatures. The AU technique has found that the critical cracking stress level is 10-15% below the level presently obtained for design purposes from analytical models. An acousto-ultrasonic stress-strain response (AUSSR) model for unidirectional and cross-ply ceramic composites was formulated. The AUSSR model predicts the strain response to increasing stress levels using real-time AU data and classical laminated plate theory. The Weibull parameters of the AUSSR model are used to calculate the design stress for thermo-structural applications. Real-time AU together with the AUSSR model was used to study the failure mechanisms of SiC/CAS ceramic composites under static and fatigue loading. An S-N curve was generated for a cross-ply SiC/CAS ceramic composite material. The AU results are corroborated and complemented by other NDE techniques, namely, in-situ optical microscope video recordings and edge replication.

Tiwari, Anil↗
NASA NTRS1996

Damage accumulation in closed cross-section, laminated, composite structures

The need for safe, lightweight, less expensive, and more reliable launch vehicle components is being driven by the competitiveness of the commercial launch market. The United States has lost 2/3 of the commercial lunch market to Europe. As low cost Russian and Chinese vehicles become available, the US market share could be reduced even further. This international climate is driving the Single Stage To Orbit (SSTO) program at NASA. The goal of the SSTO program is to radically reduce the cost of safe, routine transportation to and from space with a totally reusable launch vehicle designed for low-cost aircraft-like operations. Achieving this goal will require more efficient uses of materials. Composite materials can provide this program with the material and structural efficiencies needed to stay competitive in the international launch market place. In satellite systems the high specific properties, design flexibility, improved corrosion and wear resistance, increased fatigue life, and low coefficient of thermal expansion that are characteristic of composite materials can all be used to improve the overall satellite performance. Some of the satellites that may be able to take advantage of these performance characteristics are the Tethered Satellite Systems (TOSCIFER, AIRSEDS, TSS2, SEDS1, and SEDS2), AXAF, GRO, and the next generation Hubble Space Telescope. These materials can also be utilized in projects at the NASAIMSFC Space Optics Technology and System Center of Excellence. The successful implementation of composite materials requires accurate performance characterization. Materials characterization data for composite materials is typically generated using flat coupons of finite width. At the free edge of these coupons the stress state is exacerbated by the presence of stiffness and geometric discontinuities. The exacerbated stress state has been shown to dominate the damage accumulation in these materials and to have a profound affect on the material constants. Space structures typically have closed cross-sections, absent of free edges. As a result, composite material characterization data generated using finite width flat specimens does not accurately reflect the performance of the composite materials used in a closed cross-section structural configuration. Several investigators have recognized the need to develop characterization techniques for composite materials in closed cross-sectioned structures. In these investigations test methods were developed and cylindrical specimens were evaluated. The behavior of the cylindrical specimens were observed to depart from behavior typical of flat coupons. However, no attempts were made to identify and monitor the progression of damage in these cylindrical specimens during loading. The identification and monitoring of damage is fundamental to the characterization of composite materials in closed cross-section configurations. In the study reported here, a closed cross-sectioned test method was developed to monitor damage progression in 2 in. diameter cylindrical specimens and 1.5 in. finite width flat coupons subjected to quasi-static, tensile loading conditions. Damage in these specimen configurations was monitored using pulse echo ultrasonic, acoustic emission, and X-ray techniques.

Bucinell, Ronald B.↗