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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.

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26 records · Page 2

Cyclic debonding of adhesively bonded composites

To analyze the fatigue behavior of a simple composite-to-composite bonded joint, a combined experimental and analytical study of the cracked-lap-shear specimen subjected to constant-amplitude cyclic loading was undertaken. Two bonded systems were studied: T300/5208 graphite/epoxy adherends bonded with adhesives EC 3445 and with FM-300. For each bonded system, two specimen geometries were tested: (1) a strap adherend of 16 plies bonded to a lap adherend of 8 plies, and (2) a strap adherend of 8 plies bonded to a lap adherend of 16 plies. In all specimens tested, the fatigue failure was in the form of cyclic debonding with some 0 deg fiber pull-off from the strap adherend. The debond always grew in the region of adhesive that had the highest mode I (peel) loading and that region was close to the adhesive-strap interface. Furthermore, the measured cyclic debond growth rates correlated well with total strain energy release rates G(T) as well as with its components G(I) (peel) and G(II) (shear) for the mixed-mode loading in the present study.

Mall, S.↗

Flight tests of Viking parachute system in three Mach number regimes. 2: Parachute test results

Tests of the Viking 16.15-meter nominal-diameter disk-gap-band parachute were conducted at Mach number and dynamic pressure conditions which bracketed the range postulated for the Viking '75 mission to Mars. Parachutes were deployed at supersonic, transonic, and subsonic speeds behind a simulated Viking entry capsule. All parachutes successfully deployed, inflated, and exhibited sufficient drag and stability for mission requirements. Basic parachute data including loads, drag coefficients, pull-off angles, and canopy area ratios are presented. Trajectory reconstruction and onboard camera data methods were combined to yield continuous histories of both parachute and test-vehicle angular motions which are presented for the period from parachute deployment through steady inflation.

Bendura, R. J.↗

Adhesion in a Vacuum Environment and its Implications for Dust Mitigation Techniques on Airless Bodies

During the Apollo missions, the adhesion of dust to critical spacecraft systems was a greater problem than anticipated and resulted in functional degradation of thermal control surfaces, spacesuit seals, and other spacecraft components. Notably, Earth-based simulation efforts did not predict the magnitude and effects of dust adhesion in the lunar environment. Forty years later, we understand that the ultrahigh vacuum (UHV) environment, coupled with micrometeorite impacts and constant ion and photon bombardment from the sun result in atomically clean and high surface energy dust particles and spacecraft surfaces. However, both the dominant mechanism of adhesion in airless environments and the conditions for high fidelity simulation tests have still to be determined. The experiments presented in here aim to aid in the development of dust mitigation techniques for airless bodies (e.g., lunar surface, asteroids, moons of outer planets). The approach taken consists of (a) quantifying the adhesion between common polymer and metallic spacecraft materials and a synthetic noritic volcanic glass, as a function of surface cleanliness and of triboelectric charge transfer in a UHV environment, and (b) determining parameters for high fidelity tests through investigation of adhesion dependence on vacuum environment and sample treatment. Adhesion force has been measured between pins of spacecraft materials and a plate of synthetic volcanic glass by determining the pull-off force with a torsion balance. Although no significant adhesion is generally observed directly as a result of high surface energies, the adhesion due to induced electrostatic charge is observed to increase with spacecraft material cleanliness, in some cases by over a factor of 10. Furthermore, electrostatically-induced adhesion is found to decrease rapidly above pressures of 10-6 torr. It is concluded that high-fidelity tests should be conducted in high to ultrahigh vacuum and include an ionized surface cleaning process.

Berkebile, Stephen↗

Microstructure and Properties of Thermally Sprayed Functionally Graded Coatings for Polymeric Substrates

The use of polymer matrix composites (PMCs) in the gas flow path of advanced turbine engines offers significant benefits for aircraft engine performance but their useful lifetime is limited by their poor erosion resistance. High velocity oxy-fuel (HVOF) sprayed polymer/cermet functionally graded (FGM) coatings are being investigated as a method to address this technology gap by providing erosion and oxidation protection to polymer matrix composites. The FGM coating structures are based on a polyimide matrix filled with varying volume fractions of WC-Co. The graded coating architecture was produced using a combination of internal and external feedstock injection, via two computer-controlled powder feeders and controlled substrate preheating. Porosity, coating thickness and volume fraction of the WC-Co filler retained in the coatings were determined using standard metallographic techniques and computer image analysis. The pull-off strength (often referred to as the adhesive strength) of the coatings was evaluated according to the ASTM D 4541 standard test method, which measured the greatest normal tensile force that the coating could withstand. Adhesive/cohesive strengths were determined for three different types of coating structures and compared based on the maximum indicated load and the surface area loaded. The nature and locus of the fractures were characterized according to the percent of adhesive and/or cohesive failure, and the tested interfaces and layers involved were analyzed by Scanning Electron Microscopy.

Ivosevic, M.↗

Adhesion Between Volcanic Glass and Spacecraft Materials in an Airless Body Environment

The successful exploration of airless bodies, such as the Earth s moon, many smaller moons of the outer planets (including those of Mars) and asteroids, will depend on the development and implementation of effective dust mitigation strategies. The ultrahigh vacuum environment (UHV) on the surfaces of these bodies, coupled with constant ion and photon bombardment from the Sun and micrometeorite impacts (space weathering), makes dust adhesion to critical spacecraft systems a severe problem. As a result, the performance of thermal control surfaces, photovoltaics and mechanical systems can be seriously degraded even to the point of failure. The severe dust adhesion experienced in these environments is thought to be primarily due to two physical mechanisms, electrostatic attraction and high surface energies, but the dominant of these has yet to be determined. The experiments presented here aim to address which of these two mechanisms is dominant by quantifying the adhesion between common spacecraft materials (polycarbonate, FEP and PTFE Teflon, (DuPont) Ti-6-4) and a synthetic noritic volcanic glass, as a function of surface cleanliness and triboelectric charge transfer in a UHV environment. Adhesion force has been measured between pins of spacecraft materials and a plate of synthetic volcanic glass by determining the pull-off force with a torsion balance. Although no significant adhesion is observed directly as a result of high surface energies, the adhesion due to induced electrostatic charge is observed to increase with spacecraft material cleanliness, in some cases by over a factor of 10, although the increase is dependent on the particular material pair. The knowledge gained by these studies is envisioned to aid the development of new dust mitigation strategies and improve existing strategies by helping to identify and characterize mechanisms of glass to spacecraft adhesion for norite volcanic glass particles. Furthermore, the experience of the Apollo missions revealed that dust mitigation strategies must be subjected to high fidelity tests. To facilitate the effectiveness of ground-based testing of mitigation strategies, the issue of a pressure limit for high fidelity tests will be addressed.

Berkebile, Stephen↗

Characterizing photovoltaic backsheet adhesion degradation using the wedge and single cantilever beam tests, Part II: Accelerated tests

Photovoltaic (PV) backsheets provide critical moisture, mechanical, and electrical insulation to the backside of PV modules, but their continued functionality depends upon their ability to remain well adhered over years of harsh environmental exposure. A study of adhesive strength was conducted on several PV backsheet types exposed to indoor accelerated weathering. Two adhesion tests – the wedge test and single cantilever beam test – were used to measure adhesion energy in four backsheets: two with fluoropolymer-based outer (airside) layers – polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF) – and two with non-fluoropolymer-based outer layers–polyamide (PA) and polyethylene terephthalate (PET). The effects of changes in temperature, ultraviolet (UV) irradiance, relative humidity, and a periodic water spray were studied. The PET-, PVF- and PVDF-based backsheets all showed instances of debonding in an adhesive layer, which is commonly reported. Furthermore, for the PA-, PET-, and PVDF-based backsheets, adhesion energy dropped fairly rapidly with exposure, reaching very low levels by 4000 h. The PVF-based backsheet was relatively robust to weathering. Pull-off of an outer chalking layer in the PA- and PET-based backsheets suggested a sensitivity to UV. Adhesion in these two backsheets was also highly sensitive to changes in moisture level. Changes in UV irradiance and temperature did not show a statistically significant effect on adhesion loss for the exposure levels used. The present work is part of a two-part adhesion study on both field-weathered and indoor-exposed backsheets, and forms a basis for understanding adhesion degradation across a variety of backsheet types and degradation factors.

14 SOLAR ENERGY↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading b. The structure is able to sustain design limit load (DLL) Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions. The standard industry approach for DaDT certification adheres to the use of the traditional virtual crack closure technique (VCCT) method. VCCT is generally a preferred method because it conforms to the current certification principles of damage from a known flaw, and when used correctly, can be effective at predicting delamination propagation under static and cyclic loading. The VCCT method requires the inclusion of an initial flaw in the finite element (FE) model requiring a-priori knowledge of the flaw location. This in turn requires a plethora of analysis cases to be examined to cover a reasonable span of potential damage states. Additionally, the VCCT approach requires node-to-node connectivity rendering it incompatible with the best practices and approaches for using continuum damage mechanics (CDM) based progressive damage and failure analysis (PDFA) tools within a typical FE solver. Alternatives to VCCT have emerged in the form of cohesive elements which utilize the cohesive zone model (CZM). Unlike VCCT which models linear elastic fracture mechanics, cohesive elements couples continuum and fracture based responses through the use of bilinear traction separation laws. These laws are defined based on a penalty stiffness, a cohesive strength, and a strain energy release rate. The approach can be mesh regularized with native cohesive elements within many FE solvers such as Abaqus and LS-DYNA. In Phase I of the NASA Advanced Composites Consortium (ACC) post-buckled stiffened panel with BVID, Strength and Life [1], the performance of cohesive elements were benchmarked in comparison to VCCT and LEFM solutions and showed good agreement using Abaqus explicit [2]. To realize savings on current and future programs, it is still necessary to close technical gaps related to the use of cohesive elements with Abaqus Standard. Within a program environment, standard finite element analysis is the preferred analytical capability for quasi-static loading as it eliminates uncertainty due to oscillatory behavior commonly seen with explicit analysis. This oscillatory behavior creates difficulties in writing margins of safety based on the analysis. The use of negative tangent stiffness material models complicates convergence which typically requires the use of numerical controls such as viscous damping to overcome. To date, there has not been a comprehensive study on how to establish best practices for cohesive element convergence for predictive capability within the Abaqus implicit solver. In pursuit of these goals, under the NASA ACC program, several numerical benchmark problems were proposed including pure mode I (double cantilevered beam – DCB), pure mode II (end notch flexure – ENF), and symmetric/unsymmetric evolving mixed mode (single leg bend – SLB). This paper focuses on the use of cohesive elements to model the delamination through the use of CZM. Specifically, finite element models for the DCB, ENF, symmetric SLB, and unsymmetric SLB, are developed and various solution controls for convergence are studied to develop a best practice. Once the best practice has been developed, the predictive capability of the objective CZM model is used to analyze the hat pull-off strength of a standard hat stiffened configuration under various loading conditions.

Abaqus↗

Thermal Processing Effects on the Adhesive Strength of PS304 High Temperature Solid Lubricant Coatings

In this paper the effects of post deposition heat treatments on the cohesive and adhesive strength properties of PS304, a plasma sprayed nickel-chrome based, high temperature solid lubricant coating deposited on stainless steel, are studied. Plasma spray deposited coating samples were exposed in air at temperatures from 432 to 650 C for up to 500 hr to promote residual stress relief, enhance particle to particle bonding and increase coating to substrate bond strength. Coating pull-off strength was measured using a commercial adhesion tester that utilizes 13 mm diameter aluminum pull studs attached to the coating surface with epoxy. Pull off force was automatically recorded and converted to coating pull off strength. As deposited coating samples were also tested as a baseline. The as-deposited (untreated) samples either delaminated at the coating-substrate interface or failed internally (cohesive failure) at about 17 MPa. Samples heat treated at temperatures above 540 C for 100 hr or at 600 C or above for more than 24 hr exhibited strengths above 31 MPa, nearly a two fold increase. Coating failure occurred inside the body of the coating (cohesive failure) for nearly all of the heat-treated samples and only occasionally at the coating substrate interface (adhesive failure). Metallographic analyses of heat-treated coatings indicate that the Nickel-Chromium binder in the PS304 appears to have segregated into two phases, a high nickel matrix phase and a high chromium precipitated phase. Analysis of the precipitates indicates the presence of silicon, a constituent of a flow enhancing additive in the commercial NiCr powder. The exact nature and structure of the precipitate phase is not known. This microstructural change is believed to be partially responsible for the coating strength increase. Diffusion bonding between particles may also be playing a role. Increasing the heat treatment temperature, exposure time or both accelerate the heat treatment process. Preliminary measurements indicate that the heat treatment also results in a one time, permanent coating thickness increase of about 3%. Based upon these results, the incorporation of a heat treatment prior to final finishing has been incorporated in the application process of this coating technology.

DellaCorte, Christopher↗