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NASA NTRS1990

A New Approximate Fracture Mechanics Analysis Methodology for Composites with a Crack or Hole

A new approximate theory which links the inherent flaw concept with the theory of crack tip stress singularities at a bi-material interface was developed. Three assumptions were made: (1) the existence of inherent flaw (i.e., damage zone) at the tip of the crack, (2) a fracture of the filamentary composites initiates at a crack lying in the matrix material at the interface of the matrix/filament, and (3) the laminate fails whenever the principal load-carrying laminae fails. This third assumption implies that for a laminate consisting of 0 degree plies, cracks into matrix perpendicular to the 0 degree filaments are the triggering mechanism for the final failure. Based on this theory, a parameter bar K sub Q which is similar to the stress intensity factor for isotropic materials but with a different dimension was defined. Utilizing existing test data, it was found that bar K sub Q can be treated as a material constant. Based on this finding a fracture mechanics analysis methodology was developed. The analytical results are correlated well with test results. This new approximate theory can apply to both brittle and metal matrix composite laminates with crack or hole.

Tsai, H. C.↗

NASA NTRS2013

Dynamic Mechanical Analysis (DMA) to Help Characterize Vespel SP-211 Polyimide Material for Use as a 750 F Valve Seal on the Ares I Upper Stage J-2X Engine

DuPont(tm) Vespel(R) SP-211 polyimide was selected as the top candidate seal material for use in the Oxidizer Turbine Bypass Valve (OTBV) on NASA's Ares I Upper Stage J-2X engine. In the OTBV, the seal material would get exposed to temperatures up to 750degF for approx 10 minutes at a time. Although the J-2X engine is not reusable, the valve material could be exposed to multiple temperature cycles up to 750degF during engine operation. The Constellation Program that included the Ares I rocket was eventually cancelled, but the J-2X engine was chosen for continued use for development of NASA's Space Launch System (SLS). The SLS is a heavy-lift launch vehicle that will have capability of taking astronauts and hardware to the Moon, Mars and asteroids. Dynamic mechanical analysis (DMA) was one of several test techniques used to characterize Vespel SP-211 to help prove its worthiness for use on the OTBV of the J-2X engine.

Wingard, Doug↗

NASA NTRS2013

Dynamic Mechanical Analysis (DMA) to Help Characterize Vespel SP-211 Polyimide Material for Use as a 750 F Valve Seal on the Ares I Upper Stage J-2X Engine

DuPont (TM) Vespel (R) SP-211 polyimide was selected as the top candidate seal material for use in the Oxidizer Turbine Bypass Valve (OTBV) on NASA's Ares I Upper Stage J-2X engine. In the OTBV, the seal material would get exposed to temperatures up to 750degF for approx 10 minutes at a time. Although the J-2X engine is not reusable, the valve material could be exposed to multiple temperature cycles up to 750 F during engine operation. The Constellation Program that included the Ares I rocket was eventually cancelled, but the J-2X engine was chosen for continued use for development of NASA's Space Launch System (SLS). The SLS is a heavy-lift launch vehicle that will have capability of taking astronauts and hardware to the Moon, Mars and asteroids. Dynamic mechanical analysis (DMA) was one of several test techniques used to characterize Vespel SP-211 to help prove its worthiness for use on the OTBV of the J-2X engine.

Wingard, Doug↗

NASA NTRS1979

Dynamic mechanical analysis of fiber reinforced composites

Dynamic mechanical and thermal properties were determined for unidirectional epoxy/glass composites at various fiber orientation angles. Resonant frequency and relative logarithmic decrement were measured as functions of temperature. In low angle and longitudinal specimens a transition was observed above the resin glass transition temperature which was manifested mechanically as an additional damping peak and thermally as a change in the coefficient of thermal expansion. The new transition was attributed to a heterogeneous resin matrix induced by the fiber. The temperature span of the glass-rubber relaxation was found to broaden with decreasing orientation angle, reflecting the growth of fiber contribution and exhibiting behavior similar to that of Young's modulus. The change in resonant frequency through the glass transition was greatest for samples of intermediate fiber angle, demonstrating behavior similar to that of the longitudinal shear modulus.

Reed, K. E.↗

NASA NTRS1979

Dynamic mechanical analysis of fiber reinforced composites

Reed, K. E.↗

NASA NTRS1986

Thigmomorphogenesis: anatomical, morphological and mechanical analysis of genetically different sibs of Pinus taeda in response to mechanical perturbation

Twenty-three open pollinated families (half-sibs) and four controlled pollinated families (full-sibs) of Pinus taeda L. (loblolly pine) were grown in a greenhouse and analyzed for changes induced by mechanical perturbation (MP). These changes included inhibition of stem and needle elongation, bracing of branch nodes, and increased radial growth in the direction of the MP. Inhibition of stem elongation was the least variable feature measured. Leaf extension and stem diameter were highly variable between half-sibs. MP induced increased drag in greenhouse grown P. taeda in wind-tunnel tests. In P. taeda, MP induced decreased flexibility and increased elasticity and plasticity of the stem. The increased radial growth of the stems overrode the increase in elasticity, resulting in an overall decrease in flexibility. MP trees had a higher rupture point than non-MP controls. Increased radial growth is a result of more rapid cell divisions of the vascular cambium, resulting in increased numbers of tracheids. The decreased leader growth is partly due to a decreased tracheid length in response to MP.

Non-NASA Center↗

NASA NTRS2023

Flight Mechanics Analysis Tools Interoperability and Component Sharing

Several NASA centers have developed independent flight mechanics tools to meet the science needs of missions. This NASA Engineering and Safety Center (NESC) assessment sought to explore the ways to increase the interoperability of three specific tools: Copernicus from Johnson Space Center (JSC), the General Mission Analysis Tool (GMAT) from Goddard Spaceflight Flight Center (GSFC), and the Mission-Analysis Operations Navigation Toolkit Environment (MONTE) from the Jet Propulsion Laboratory (JPL). Before this assessment, these tools were not integrated and could not easily share data, models, or components. This report contains the outcome of the NESC assessment.

General Mission Analysis Tool↗

NASA NTRS2010

Space Shuttle Orbiter Wing-Leading-Edge Panel Thermo-Mechanical Analysis for Entry Conditions

Linear elastic, thermo-mechanical stress analyses of the Space Shuttle Orbiter wing-leading-edge panels is presented for entry heating conditions. The wing-leading-edge panels are made from reinforced carbon-carbon and serve as a part of the overall thermal protection system. Three-dimensional finite element models are described for three configurations: integrated configuration, an independent single-panel configuration, and a local lower-apex joggle segment. Entry temperature conditions are imposed and the through-the-thickness response is examined. From the integrated model, it was concluded that individual panels can be analyzed independently since minimal interaction between adjacent components occurred. From the independent single-panel model, it was concluded that increased through-the-thickness stress levels developed all along the chord of a panel s slip-side joggle region, and hence isolated local joggle sections will exhibit the same trend. From the local joggle models, it was concluded that two-dimensional plane-strain models can be used to study the influence of subsurface defects along the slip-side joggle region of these panels.

Knight, Norman F., Jr.↗

NASA NTRS1977

Crater modification by gravity - A mechanical analysis of slumping

An analysis of the stability of a crater from a mechanical point of view indicates that the observed slumping of lunar craters requires a perfectly plastic constitutive relation for the lunar surface rock. The angle of internal friction of this material must be less than a few degrees. The evidence for a perfectly plastic constitutive relation is described, and a simplified model of a crater in a perfectly plastic medium is used to investigate the nature of its collapse. Crater stability is found to depend principally upon a dimensionless parameter equal to the product of the density, acceleration of gravity, and depth divided by the yield strength. Criteria for stability, 'slope failures', and 'floor failures' are reported.

Melosh, H. J.↗

NASA NTRS1992

Fracture mechanics analysis for various fiber/matrix interface loadings

Fiber/matrix (F/M) cracking was analyzed to provide better understanding and guidance in developing F/M interface fracture toughness tests. Two configurations, corresponding to F/M cracking at a broken fiber and at the free edge, were investigated. The effects of mechanical loading, thermal cooldown, and friction were investigated. Each configuration was analyzed for two loadings: longitudinal and normal to the fiber. A nonlinear finite element analysis was performed to model friction and slip at the F/M interface. A new procedure for fitting a square-root singularity to calculated stresses was developed to determine stress intensity factors (K sub I and K sub II) for a bimaterial interface crack. For the case of F/M cracking at a broken fiber with longitudinal loading, crack tip conditions were strongly influenced by interface friction. As a result, an F/M interface toughness test based on this case was not recommended because nonlinear data analysis methods would be required. For the free edge crack configuration, both mechanical and thermal loading caused crack opening, theory avoiding fractional effects. A F/M interface toughness test based on this configuration would provide data for K(sub I/K(sub II) ratios of about 0.7 and 1.6 for fiber and radial normal loading, respectively. However, thermal effects must be accounted for in the data analysis.

Naik, Rajiv A.↗

NASA NTRS1991

Fracture mechanics analysis for various fiber/matrix interface loadings

Fiber/matrix (F/M) cracking was analyzed to provide better understanding and guidance in developing F/M interface fracture toughness tests. Two configurations, corresponding to F/M cracking at a broken fiber and at the free edge, were investigated. The effects of mechanical loading, thermal cooldown, and friction were investigated. Each configuration was analyzed for two loadings: longitudinal and normal to the fiber. A nonlinear finite element analysis was performed to model friction and slip at the F/M interface. A new procedure for fitting a square-root singularity to calculated stresses was developed to determine stress intensity factors (K sub I and K sub II) for a bimaterial interface crack. For the case of F/M cracking at a broken fiber with longitudinal loading, crack tip conditions were strongly influenced by interface friction. As a result, an F/M interface toughness test based on this case was not recommended because nonlinear data analysis methods would be required. For the free edge crack configuration, both mechanical and thermal loading caused crack opening, thereby avoiding frictional effects. A F/M interface toughness test based on this configuration would provide data for K(sub I)/K(sub II) ratios of about 0.7 and 1.6 for fiber and radial normal loading, respectively. However, thermal effects must be accounted for in the data analysis.

Naik, R. A.↗

NASA NTRS1991

Fracture mechanics analysis for various fiber/matrix interface loadings

Fiber/matrix (F/M) cracking was analyzed to provide better understanding and guidance in developing F/M interface fracture toughness tests. Two configurations, corresponding to F/M cracking at a broken fiber and at the free edge, were investigated. The effects of mechanical loading, thermal cooldown, and friction were investigated. Each configuration was analyzed for two loadings: longitudinal and normal to the fiber. A nonlinear finite element analysis was performed to model friction and slip at the F/M interface. A new procedure for fitting a square-root singularity to calculated stresses was developed to determine stress intensity factors (K sub I and K sub II) for a bimaterial interface crack. For the case of F/M cracking at a broken fiber with longitudinal loading, crack tip conditions were strongly influenced by interface friction. As a result, an F/M interface toughness test based on this case was not recommended because nonlinear data analysis methods would be required. For the free edge crack configuration, both mechanical and thermal loading caused crack opening, thereby avoiding frictional effects. An F/M interface toughness test based on this configuration would provide data for K(sub I)/K(sub II) ratios of about 0.7 and 1.6 for fiber and radial normal loading, respectively. However, thermal effects must be accounted for in the data analysis.

Naik, R. A.↗

NASA NTRS1998

An Integrated Tool for the Coupled Thermal and Mechanical Analysis of Pyrolyzing Heatshield Materials

Materials that pyrolyze at elevated temperature have been commonly used as thermal protection materials in hypersonic flight, and advanced pyrolyzing materials for this purpose continue to be developed. Because of the large temperature gradients that can arise in thermal protection materials, significant thermal stresses can develop. Advanced applications of pyrolytic materials are calling for more complex heatshield configurations, making accurate thermal stress analysis more important, and more challenging. For non-pyrolyzing materials, many finite element codes are available and capable of performing coupled thermal-mechanical analyses. These codes do not, however, have a built-in capability to perform analyses that include pyrolysis effects. When a pyrolyzing material is heated, one or more components of the original virgin material pyrolyze and create a gas. This gas flows away from the pyrolysis zone to the surface, resulting in a reduction in surface heating. A porous residue, referred to as char, remains in place of the virgin material. While the processes involved can be complex, it has been found that a simple physical model in which virgin material reacts to form char and pyrolysis gas, will yield satisfactory analytical results. Specifically, the effects that must be modeled include: (1) Variation of thermal properties (density, specific heat, thermal conductivity) as the material composition changes; (2) Energy released or absorbed by the pyrolysis reactions; (3) Energy convected by the flow of pyrolysis gas from the interior to the surface; (4) The reduction in surface heating due to surface blowing; and (5) Chemical and mass diffusion effects at the surface between the pyrolysis gas and edge gas Computational tools for the one-dimensional thermal analysis these materials exist and have proven to be reliable design tools. The objective of the present work is to extend the analysis capabilities of pyrolyzing materials to axisymmetric configurations, and to couple thermal and mechanical analyses so that thermal stresses may be efficiently and accurately calculated.

Pronchick, Stephen W.↗

NASA NTRS1974

Fracture mechanics analysis of a high-pressure hydrogen facility compressor

The investigation and analysis of a high-pressure hydrogen facility compressor is chronicled, and a life prediction based on fracture mechanics is presented. Crack growth rates in SA 105 Gr II steel are developed for the condition of sustained loading, using a hypothesis of hydrogen embrittlement associated with plastic zone reverse yielding. The resultant formula is compared with test data obtained from laboratory specimens.

Vroman, G. A.↗

NASA NTRS1999

Some Aspects on the Mechanical Analysis of Micro-Shutters

An array of individually addressable micro-shutters is being designed for spectroscopic applications. Details of the design are presented in a companion paper. The mechanical design of a single shutter element has been completed. This design consists of a shutter blade suspended on a torsion beam manufactured out of single crystal silicon membranes. During operation the shutter blade will be rotated by 90 degrees out of the array plane. Thus, the stability and durability of the beams are crucial for the reliability of the devices. Structures were fabricated using focused ion beam milling in a FEI 620 dual beam machine, and subsequent testing was completed using the same platform. This allowed for short turn around times. We performed torsion and bending experiments to determine key characteristics of the membrane material. Results of measurements on prototype shutters were compared with the predictions of the numerical models. The data from these focused studies were used in conjunction with experiments and numerical models of shutter prototypes to optimize the design. In this work, we present the results of the material studies, and assess the mechanical performance of the resulting design.

Fettig, Rainer K.↗

NASA NTRS1986

Tether pointing platform and space elevator mechanisms analysis of the key concepts for SATP and scaled SATP

The key concepts for a scaled and full model Science and Applications Tethered Platform (SATP) are analysized. This includes a tether pointing platform and a space elevator. The mechanism concepts and technological solutions are given. The idea of the tether pointing platform mechanism is to control and stabilize the attitude of a platform by means of a movable tether. The idea of the space elevator mechanism for a scaled SATP is to drag the tether gripping it between two rotating wheels.

Turci, E.↗

NASA NTRS1991

Micro-mechanical analysis of damage growth and fracture in discontinuous fiber reinforced metal matrix composites

An experimental verification is presented for a new two parameter fracture model based on the equivalent remote biaxial stresses (ERBS). A detailed comparison is made between the new theory and the constant K(sub IC) approach of linear elastic fracture mechanics (LEFM). Fracture is predicted through a failure curve representing the change in a variable fracture toughness K(sub IC) with the ERBS ratio B(sub E). The nonsingular term (T) in the series expansion of the near crack-tip transverse stress is included in the model. Experimental results for polymethyl methacrylate (PPMA) show that the theory can account for the effects of geometry on fracture toughness as well as indicate the initiation of crack branching. It is shown that the new criterion predicts failure for PMMA with a 95 percent confidence zone which is nearly three times smaller than that of the LEFM K(sub IC) approach.

Goree, James G.↗

NASA NTRS2006

Fracture Mechanics Analysis of LH2 Feed Line Flow Liners

Inspections of the Space Shuttle Main Engine revealed fatigue cracks growing from slots in the flow liner of the liquid hydrogen (LH2) feed lines. During flight, the flow liners experience complex loading induced by flow of LH2 and the resonance characteristics of the structure. The flow liners are made of Inconel 718 and had previously not been considered a fracture critical component. However, fatigue failure of a flow liner could have catastrophic effect on the Shuttle engines. A fracture mechanics study was performed to determine if a damage tolerance approach to life management was possible and to determine the sensitivity to the load spectra, material properties, and crack size. The load spectra were derived separately from ground tests and material properties were obtained from coupon tests. The stress-intensity factors for the fatigue cracks were determined from a shell-dynamics approach that simulated the dominant resonant frequencies. Life predictions were obtained using the NASGRO life prediction code. The results indicated that adequate life could not be demonstrated for initial crack lengths of the size that could be detected by traditional NDE techniques.

James, Mark A.↗