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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Reliability Sensitivity Analysis and Design Optimization of Composite Structures Based on Response Surface Methodology

This report discusses the development and application of two alternative strategies in the form of global and sequential local response surface (RS) techniques for the solution of reliability-based optimization (RBO) problems. The problem of a thin-walled composite circular cylinder under axial buckling instability is used as a demonstrative example. In this case, the global technique uses a single second-order RS model to estimate the axial buckling load over the entire feasible design space (FDS) whereas the local technique uses multiple first-order RS models with each applied to a small subregion of FDS. Alternative methods for the calculation of unknown coefficients in each RS model are explored prior to the solution of the optimization problem. The example RBO problem is formulated as a function of 23 uncorrelated random variables that include material properties, thickness and orientation angle of each ply, cylinder diameter and length, as well as the applied load. The mean values of the 8 ply thicknesses are treated as independent design variables. While the coefficients of variation of all random variables are held fixed, the standard deviations of ply thicknesses can vary during the optimization process as a result of changes in the design variables. The structural reliability analysis is based on the first-order reliability method with reliability index treated as the design constraint. In addition to the probabilistic sensitivity analysis of reliability index, the results of the RBO problem are presented for different combinations of cylinder length and diameter and laminate ply patterns. The two strategies are found to produce similar results in terms of accuracy with the sequential local RS technique having a considerably better computational efficiency.

Rais-Rohani, Masoud↗
NASA NTRS1994

Probability techniques for reliability analysis of composite materials

Traditional design approaches for composite materials have employed deterministic criteria for failure analysis. New approaches are required to predict the reliability of composite structures since strengths and stresses may be random variables. This report will examine and compare methods used to evaluate the reliability of composite laminae. The two types of methods that will be evaluated are fast probability integration (FPI) methods and Monte Carlo methods. In these methods, reliability is formulated as the probability that an explicit function of random variables is less than a given constant. Using failure criteria developed for composite materials, a function of design variables can be generated which defines a 'failure surface' in probability space. A number of methods are available to evaluate the integration over the probability space bounded by this surface; this integration delivers the required reliability. The methods which will be evaluated are: the first order, second moment FPI methods; second order, second moment FPI methods; the simple Monte Carlo; and an advanced Monte Carlo technique which utilizes importance sampling. The methods are compared for accuracy, efficiency, and for the conservativism of the reliability estimation. The methodology involved in determining the sensitivity of the reliability estimate to the design variables (strength distributions) and importance factors is also presented.

Wetherhold, Robert C.↗
NASA NTRS2011

Reliability-Based Design Optimization of a Composite Airframe Component

A stochastic optimization methodology (SDO) has been developed to design airframe structural components made of metallic and composite materials. The design method accommodates uncertainties in load, strength, and material properties that are defined by distribution functions with mean values and standard deviations. A response parameter, like a failure mode, has become a function of reliability. The primitive variables like thermomechanical loads, material properties, and failure theories, as well as variables like depth of beam or thickness of a membrane, are considered random parameters with specified distribution functions defined by mean values and standard deviations.

Pai, Shantaram S.↗
NASA NTRS1994

Design of a composite filter realizable on practical spatial light modulators

Hybrid optical correlator systems use two spatial light modulators (SLM's), one at the input plane and the other at the filter plane. Currently available SLM's such as the deformable mirror device (DMD) and liquid crystal television (LCTV) SLM's exhibit arbitrarily constrained operating characteristics. The pattern recognition filters designed with the assumption that the SLM's have ideal operating characteristic may not behave as expected when implemented on the DMD or LCTV SLM's. Therefore it is necessary to incorporate the SLM constraints in the design of the filters. In this report, an iterative method is developed for the design of an unconstrained minimum average correlation energy (MACE) filter. Then using this algorithm a new approach for the design of a SLM constrained distortion invariant filter in the presence of input SLM is developed. Two different optimization algorithms are used to maximize the objective function during filter synthesis, one based on the simplex method and the other based on the Hooke and Jeeves method. Also, the simulated annealing based filter design algorithm proposed by Khan and Rajan is refined and improved. The performance of the filter is evaluated in terms of its recognition/discrimination capabilities using computer simulations and the results are compared with a simulated annealing optimization based MACE filter. The filters are designed for different LCTV SLM's operating characteristics and the correlation responses are compared. The distortion tolerance and the false class image discrimination qualities of the filter are comparable to those of the simulated annealing based filter but the new filter design takes about 1/6 of the computer time taken by the simulated annealing filter design.

Rajan, P. K.↗
NASA NTRS1982

Development of design allowable data for Celion 6000/LARC-160, graphite/polyimide composite laminates

A design allowables test program was conducted on Celion 6000/LARC-160 graphite polyimide composite to establish material performance over a 116 K (-250 F) to 589 K (600 F) temperature range. Tension, compression, in-plane shear and short beam shear properties were determined for uniaxial, quasi-isotropic and + or - 45 deg laminates. Effects of thermal aging and moisture saturation on mechanical properties were also evaluated. Celion 6000/LARC-160 graphite/polyimide can be considered an acceptable material system for structural applications to 589 K (600 F).

Ehret, R. M.↗
NASA NTRS2005

Damage-Tolerant, Affordable Composite Engine Cases Designed and Fabricated

An integrated team of NASA personnel, Government contractors, industry partners, and university staff have developed an innovative new technology for commercial fan cases that will substantially influence the safety and efficiency of future turbine engines. This effective team, under the direction of the NASA Glenn Research Center and with the support of the Federal Aviation Administration, has matured a new class of carbon/polymer composites and demonstrated a 30- to 50-percent improvement in specific containment capacity (blade fragment kinetic energy/containment system weight). As the heaviest engine component, the engine case/containment system greatly affects both the safety and efficiency of aircraft engines. The ballistic impact research team has developed unique test facilities and methods for screening numerous candidate material systems to replace the traditional heavy, metallic engine cases. This research has culminated in the selection of a polymer matrix composite reinforced with triaxially braided carbon fibers and technology demonstration through the fabrication of prototype engine cases for three major commercial engine manufacturing companies.

Hopkins, Dale A.↗
DOE OSTI2025

A deep learning and finite element approach for exploration of inverse structure–property designs of lightweight hybrid composites

Hybrid composites have important applications, such as high-performance and lightweight materials in aerospace and automotive industries. Hybrid composites utilize the synergy of diverse fillers to achieve desired material properties, but usually have more complicated microstructures. While topology optimization can optimize a particular property, designing hybrid composites for customized mechanical performances, e.g. full-range stress–strain curve, remains challenging. Here, a computational framework that integrated finite element analysis (FEA) and artificial intelligence (AI) methods of Conditional Generative Adversarial Networks (cGAN) deep learning and transfer learning was developed to establish inverse structure–property relationships and design tailor-made hybrid composites. Based on FEA-generated datasets of hybrid fiber-particle–matrix microstructures and their corresponding full-range stress–strain curves, a cGAN architecture was trained to generate tailored microstructures and establish structure–property relationships. Similarity in microstructural features and well-matched stress–strain curves based on the AI-generated composites were achieved. In conclusion, transfer learning was used to expand the pre-trained model for designing different materials systems.

Hybrid composites↗
NASA NTRS2011

A Multiscale, Nonlinear, Modeling Framework Enabling the Design and Analysis of Composite Materials and Structures

A framework for the multiscale design and analysis of composite materials and structures is presented. The ImMAC software suite, developed at NASA Glenn Research Center, embeds efficient, nonlinear micromechanics capabilities within higher scale structural analysis methods such as finite element analysis. The result is an integrated, multiscale tool that relates global loading to the constituent scale, captures nonlinearities at this scale, and homogenizes local nonlinearities to predict their effects at the structural scale. Example applications of the multiscale framework are presented for the stochastic progressive failure of a SiC/Ti composite tensile specimen and the effects of microstructural variations on the nonlinear response of woven polymer matrix composites.

Bednarcyk, Brett A.↗
NASA NTRS2012

A Multiscale, Nonlinear, Modeling Framework Enabling the Design and Analysis of Composite Materials and Structures

A framework for the multiscale design and analysis of composite materials and structures is presented. The ImMAC software suite, developed at NASA Glenn Research Center, embeds efficient, nonlinear micromechanics capabilities within higher scale structural analysis methods such as finite element analysis. The result is an integrated, multiscale tool that relates global loading to the constituent scale, captures nonlinearities at this scale, and homogenizes local nonlinearities to predict their effects at the structural scale. Example applications of the multiscale framework are presented for the stochastic progressive failure of a SiC/Ti composite tensile specimen and the effects of microstructural variations on the nonlinear response of woven polymer matrix composites.

Bednarcyk, Brett A.↗
NASA NTRS1989

Test methods and design allowables for fibrous composites. Volume 2

Topics discussed include extreme/hostile environment testing, establishing design allowables, and property/behavior specific testing. Papers are presented on environmental effects on the high strain rate properties of graphite/epoxy composite, the low-temperature performance of short-fiber reinforced thermoplastics, the abrasive wear behavior of unidirectional and woven graphite fiber/PEEK, test methods for determining design allowables for fiber reinforced composites, and statistical methods for calculating material allowables for MIL-HDBK-17. Attention is also given to a test method to measure the response of composite materials under reversed cyclic loads, a through-the-thickness strength specimen for composites, the use of torsion tubes to measure in-plane shear properties of filament-wound composites, the influlence of test fixture design on the Iosipescu shear test for fiber composite materials, and a method for monitoring in-plane shear modulus in fatigue testing of composites.

Chamis, Christos C.↗
NASA NTRS1980

Design and analysis of a stiffened composite fuselage panel

The design and analysis of stiffened composite panel that is representative of the fuselage structure of existing wide bodied aircraft is discussed. The panel is a minimum weight design, based on the current level of technology and realistic loads and criteria. Several different stiffener configurations were investigated in the optimization process. The final configuration is an all graphite/epoxy J-stiffened design in which the skin between adjacent stiffeners is permitted to buckle under design loads. Fail safe concepts typically employed in metallic fuselage structure have been incorporated in the design. A conservative approach has been used with regard to structural details such as skin/frame and stringer/frame attachments and other areas where sufficient design data was not available.

Dickson, J. N.↗
NASA NTRS1974

Analysis and design of advanced composite bounded joints

Advances in the analysis of adhesive-bonded joints are presented with particular emphasis on advanced composite structures. The joints analyzed are of double-lap, single-lap, scarf, stepped-lap and tapered-lap configurations. Tensile, compressive, and in-plane shear loads are covered. In addition to the usual geometric variables, the theory accounts for the strength increases attributable to adhesive plasticity (in terms of the elastic-plastic adhesive model) and the joint strength reductions imposed by imbalances between the adherends. The solutions are largely closed-form analytical results, employing iterative solutions on a digital computer for the more complicated joint configurations. In assessing the joint efficiency, three potential failure modes are considered. These are adherend failure outside the joint, adhesive failure in shear, and adherend interlaminar tension failure (or adhesive failure in peel). Each mode is governed by a distinct mathematical analysis and each prevails throughout different ranges of geometric sizes and proportions.

Hart-Smith, L. J.↗
NASA NTRS1990

Flat tensile specimen design for advanced composites

Finite element analyses of flat, reduced gage section tensile specimens with various transition region contours were performed. Within dimensional constraints, such as maximum length, tab region width, gage width, gage length, and minimum tab length, a transition contour radius of 41.9 cm produced the lowest stress values in the specimen transition region. The stresses in the transition region were not sensitive to specimen material properties. The stresses in the tab region were sensitive to specimen composite and/or tab material properties. An evaluation of stresses with different specimen composite and tab material combinations must account for material nonlinearity of both the tab and the specimen composite. Material nonlinearity can either relieve stresses in the composite under the tab or elevate them to cause failure under the tab.

Worthem, Dennis W.↗