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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 NTRS1991

Free vibrations of delaminated beams

Free vibration of laminated composite beams is studied. The effect of interply delaminations on natural frequencies and mode shapes is evaluated both analytically and experimentally. The equation of motion and associated boundary conditions are derived for the free vibration of a composite beam with a delamination of arbitrary size and location. A generalized variational principle is used to formulate the equation of motion, taking into account the interlaminar stress concentration at the crack-tips. This is accomplished by introducing a 'crack function' into the beam's compatibility relations. This function has its maximum value at the crack tip and decays exponentially in the longitudinal direction. The rate of exponential decay is determined by a least-square fit with the experimental results. The effect of coupling between longitudinal vibration and bending vibration is considered in the present study. This coupling effect is found to significantly affect the natural frequencies and mode shapes of the delaminated beam.

Shen, M.-H. H.↗
NASA NTRS1992

Progress in integrated analysis with adaptive unstructured meshing

Design of lightweight structures and thermal protection systems for hypersonic vehicles depend on accurate prediction of aerothermal loads, structural temperatures and their gradients, and structural deformations and stresses. Concentration is on an alternative meshing technique which generates an entirely new adaptive unstructured mesh based on the solution obtained from the earlier mesh. The technique combined with the finite element method has been shown to significantly improve the efficiency and accuracy of the fluid, thermal, and structural analyses. Current capability of the adaptive unstructured meshing technique for the integrated fluid-thermal-structural analysis is described first. The technique was extended to transient thermal analysis of structures with time-dependent adaptive meshing to capture the detailed temperature response with a minimum number of unknowns and computational cost. Both linear and higher-order finite elements are implemented to demonstrate the generality of the technique and to investigate their solution accuracy. Currently, the adaptive meshing technique is being developed for plane structures that can be modeled with membrane elements and built-up structures modeled with membrane and bending elements. The capability of the technique to these different disciplinary problems is demonstrated by several examples.

Dechaumphai, Pramote↗
NASA NTRS1992

Optimal design of geodesically stiffened composite cylindrical shells

An optimization system based on the finite element code Computations Structural Mechanics (CSM) Testbed and the optimization program, Automated Design Synthesis (ADS), is described. The optimization system can be used to obtain minimum-weight designs of composite stiffened structures. Ply thickness, ply orientations, and stiffener heights can be used as design variables. Buckling, displacement, and material failure constraints can be imposed on the design. The system is used to conduct a design study of geodesically stiffened shells. For comparison purposes, optimal designs of unstiffened shells and shells stiffened by rings and stingers are also obtained. Trends in the design of geodesically stiffened shells are identified. An approach to include local stress concentrations during the design optimization process is then presented. The method is based on a global/local analysis technique. It employs spline interpolation functions to determine displacements and rotations from a global model which are used as 'boundary conditions' for the local model. The organization of the strategy in the context of an optimization process is described. The method is validated with an example.

Gendron, G.↗
NASA NTRS1992

Fatigue mechanics - An assessment of a unified approach to life prediction

Consideration is given to the development of a total-life prediction methodology for aerospace structures based solely on crack propagation from a microstructural defect at stress concentrations. Crack-growth lives were calculated for a given loading condition by integrating the crack-growth-rate-against-delta K relationships for crack growth from a microstructural defect size to failure. Both small- and large-crack growth rate data were used. The assessment was based on data on 2024-T3 aluminum alloy, 2090-T8E41 aluminum-lithium alloy, annealed Ti-6Al-4V titanium alloy, and high-strength 4340 steel under either constant-amplitude or spectrum loading. Good agreement was found between fatigue lives measured on notched specimens with those computed from the total-life analysis.

Newman, J. C., Jr.↗
NASA NTRS1992

Mechanics of anisotropic plates and shells - A new look at an old subject

A number of aspects of the mechanics of anisotropic plates and shells are discussed. The topics covered include computational models of anisotropic plates and shells, consequences of anisotropy on deformation couplings, symmetry types, stress concentrations and edge effects, and importance of transverse shear deformation; recent applications and recent advances in the modeling and analysis of anisotropic plates and shells; and new research directions.

Noor, A. K.↗
NASA NTRS1993

Micromechanics of crenulated fibers in carbon/carbon composites

The influence of crenulated noncircular fibers on the micromechanical stress states due to a transverse strain and to a temperature change in carbon/carbon composites is examined using the finite element method. Stresses at the interface of both fully bonded and fully disbonded fibers having two crenulation amplitudes and with two fiber volume fractions are presented. In each case, these interface stresses are compared to stresses at the interface of circular fibers which have the same degree of disbond and fiber volume fraction and are under the same loading conditions. For the disbonded cases, deformed meshes showing locations of fiber/matrix contact are also included. In addition to the interface stress states, selected composite properties are also computed and compared in each case examined. Interest in studying noncircular fibers stems from a desire to increase the transverse properties of carbon/carbon by introducing a mechanical interlocking between the fiber and the matrix. Results presented here indicate that this interlocking does in fact occur. Evidence from the interface stress data suggests, however, that any possible advantage of this interlocking may be outweighed by the disadvantage of stress concentrations which arise at the interface due to the crenulated geometry of the fibers.

Carapella, E. E.↗
NASA NTRS1993

Optimal design of composite hip implants using NASA technology

Using an adaptation of NASA software, we have investigated the use of numerical optimization techniques for the shape and material optimization of fiber composite hip implants. The original NASA inhouse codes, were originally developed for the optimization of aerospace structures. The adapted code, which was called OPORIM, couples numerical optimization algorithms with finite element analysis and composite laminate theory to perform design optimization using both shape and material design variables. The external and internal geometry of the implant and the surrounding bone is described with quintic spline curves. This geometric representation is then used to create an equivalent 2-D finite element model of the structure. Using laminate theory and the 3-D geometric information, equivalent stiffnesses are generated for each element of the 2-D finite element model, so that the 3-D stiffness of the structure can be approximated. The geometric information to construct the model of the femur was obtained from a CT scan. A variety of test cases were examined, incorporating several implant constructions and design variable sets. Typically the code was able to produce optimized shape and/or material parameters which substantially reduced stress concentrations in the bone adjacent of the implant. The results indicate that this technology can provide meaningful insight into the design of fiber composite hip implants.

Blake, T. A.↗
NASA NTRS1991

Indigenous lunar construction materials

The utilization of local resources for the construction and operation of a lunar base can significantly reduce the cost of transporting materials and supplies from Earth. The feasibility of processing lunar regolith to form construction materials and structural components is investigated. A preliminary review of potential processing methods such as sintering, hot-pressing, liquification, and cast basalt techniques, was completed. The processing method proposed is a variation on the cast basalt technique. It involves liquification of the regolith at 1200-1300 C, casting the liquid into a form, and controlled cooling. While the process temperature is higher than that for sintering or hot-pressing (1000-1100 C), this method is expected to yield a true engineering material with low variability in properties, high strength, and the potential to form large structural components. A scenario for this processing method was integrated with a design for a representative lunar base structure and potential construction techniques. The lunar shelter design is for a modular, segmented, pressurized, hemispherical dome which could serve as habitation and laboratory space. Based on this design, estimates of requirements for power, processing equipment, and construction equipment were made. This proposed combination of material processing method, structural design, and support requirements will help to establish the feasibility of lunar base construction using indigenous materials. Future work will refine the steps of the processing method. Specific areas where more information is needed are: furnace characteristics in vacuum; heat transfer during liquification; viscosity, pouring and forming behavior of molten regolith; design of high temperature forms; heat transfer during cooling; recrystallization of basalt; and refinement of estimates of elastic moduli, compressive and tensile strength, thermal expansion coefficient, thermal conductivity, and heat capacity. The preliminary design of the lunar shelter showed us that joining is a critical technology needed for building a structure from large segments. The problem of joining is important to the design of any structure that is not completely prefabricated. It is especially important when the structure is subjected to tensile loading by an internal pressure. For a lunar shelter constructed from large segments the joints between these large segments must be strong, and they must permit automated construction. With a cast basalt building material which is brittle, there is the additional problem of connecting the joint with the material and avoiding stress concentration that would cause failure. Thus, a well-defined project which we intend to pursue during this coming year is the design of joints for cast basalt structural elements.

Rogers, Wayne P.↗
NASA NTRS1992

Design for progressive fracture in composite shell structures

The load carrying capability and structural behavior of composite shell structures and stiffened curved panels are investigated to provide accurate early design loads. An integrated computer code is utilized for the computational simulation of composite structural degradation under practical loading for realistic design. Damage initiation, growth, accumulation, and propagation to structural fracture are included in the simulation. Progressive fracture investigations providing design insight for several classes of composite shells are presented. Results demonstrate the significance of local defects, interfacial regions, and stress concentrations on the structural durability of composite shells.

Minnetyan, Levon↗
NASA NTRS1992

Design for inadvertent damage in composite laminates

Simplified predictive methods and models to computationally simulate durability and damage in polymer matrix composite materials/structures are described. The models include (1) progressive fracture, (2) progressively damaged structural behavior, (3) progressive fracture in aggressive environments, (4) stress concentrations, and (5) impact resistance. Several examples are included to illustrate applications of the models and to identify significant parameters and sensitivities. Comparisons with limited experimental data are made.

Singhal, Surendra N.↗
NASA NTRS1943

Effect of Rivet Pitch upon the Fatigue Strength of Single-row Riveted Joints of 0.025- to 0.025-inch 24S-T Alclad

S-N curves at the range ratio of 0.2 were experimentally obtained for each of the following values of rivet pitch P as used in a single-row lap joint of 0.025- to 0.025-inch 24S-T alclad with one-eight AN430 round-head rivets: p=0.5, 0.75, 1.0, 1.5. Families of constant rivet pitch curves, which define the fatigue life for specimens studied, were developed. Curves showing the variation of the effective stress concentration factor in fatigue with rivet pitch and maximum load per rivet were also established.

Seliger, Victor↗
NASA NTRS1993

Proposed framework for thermomechanical life modeling of metal matrix composites

The framework of a mechanics of materials model is proposed for thermomechanical fatigue (TMF) life prediction of unidirectional, continuous-fiber metal matrix composites (MMC's). Axially loaded MMC test samples are analyzed as structural components whose fatigue lives are governed by local stress-strain conditions resulting from combined interactions of the matrix, interfacial layer, and fiber constituents. The metallic matrix is identified as the vehicle for tracking fatigue crack initiation and propagation. The proposed framework has three major elements. First, TMF flow and failure characteristics of in situ matrix material are approximated from tests of unreinforced matrix material, and matrix TMF life prediction equations are numerically calibrated. The macrocrack initiation fatigue life of the matrix material is divided into microcrack initiation and microcrack propagation phases. Second, the influencing factors created by the presence of fibers and interfaces are analyzed, characterized, and documented in equation form. Some of the influences act on the microcrack initiation portion of the matrix fatigue life, others on the microcrack propagation life, while some affect both. Influencing factors include coefficient of thermal expansion mismatch strains, residual (mean) stresses, multiaxial stress states, off-axis fibers, internal stress concentrations, multiple initiation sites, nonuniform fiber spacing, fiber debonding, interfacial layers and cracking, fractured fibers, fiber deflections of crack fronts, fiber bridging of matrix cracks, and internal oxidation along internal interfaces. Equations exist for some, but not all, of the currently identified influencing factors. The third element is the inclusion of overriding influences such as maximum tensile strain limits of brittle fibers that could cause local fractures and ensuing catastrophic failure of surrounding matrix material. Some experimental data exist for assessing the plausibility of the proposed framework.

Halford, Gary R.↗
NASA NTRS1993

Three-dimensional analysis of anisotropic spatially reinforced structures

The material-adaptive three-dimensional analysis of inhomogeneous structures based on the meso-volume concept and application of deficient spline functions for displacement approximations is proposed. The general methodology is demonstrated on the example of a brick-type mosaic parallelepiped arbitrarily composed of anisotropic meso-volumes. A partition of each meso-volume into sub-elements, application of deficient spline functions for a local approximation of displacements and, finally, the use of the variational principle allows one to obtain displacements, strains, and stresses at anypoint within the structural part. All of the necessary external and internal boundary conditions (including the conditions of continuity of transverse stresses at interfaces between adjacent meso-volumes) can be satisfied with requisite accuracy by increasing the density of the sub-element mesh. The application of the methodology to textile composite materials is described. Several numerical examples for woven and braided rectangular composite plates and stiffened panels under transverse bending are considered. Some typical effects of stress concentrations due to the material inhomogeneities are demonstrated.

Bogdanovich, Alexander E.↗
NASA NTRS1994

Evaluation of oxide-coated iridium-rhenium chambers

Iridium-coated rhenium (Ir-Re) provides long life operation of radiation-cooled rockets at temperatures up to 2200 C. Ceramic oxide coatings could be used to increase Ir-Re rocket lifetimes and allow operation in highly oxidizing environments. Ceramic oxide coatings promise to serve as both thermal and diffusion barriers for the iridium layer. Seven ceramic oxide-coated Ir-Re, 22-N rocket chambers were tested with gaseous hydrogen/gaseous oxygen (GHz/G02) propellants. Five chambers had thick (over 10 mils), monolithic coatings of either hafnia (HfO2) or zirconia (ZrO2). Two chambers had coatings with thicknesses less than 5 mils. One of these chambers had a thin-walled coating of ZrO2 infiltrated with sol gel HfO2. The other chamber had a coating composed of an Ir-oxide composite. The purpose of this test program was to assess the ability of the oxide coatings to withstand the thermal shock of combustion initiation, adhere under repeated thermal cycling, and operate in aggressively oxidizing environments. All of the coatings survived the thermal shock of combustion and demonstrated operation at mixture ratios up to 11. Testing the Ir-oxide composite-coated chamber included over 29 min at mixture ratio 16. The thicker walled coatings provided the larger temperature drops across the oxide layer (up to 570 C), but were susceptible to macrocracking and eventual chipping at a stress concentrator. The cracks apparently resealed during firing, under compression of the oxide layer. The thinner walled coatings did not experience the macrocracking and chipping of the chambers that was seen with the thick, monolithic coatings. However, burn-throughs in the throat region did occur in both of the thin-walled chambers at mixture ratios well above stoichiometric. The burn-throughs were probably the result of oxygen diffusion through the oxide coating that allowed the underlying Ir and Re layers to be oxidized. The results of this test program indicated that the thin-walled oxide coatings are better suited for repeated thermal cycling than the thick-walled coating, while thicker coatings may be required for operation in aggressively oxidizing environments.

Reed, Brian D.↗
NASA NTRS1993

The impact of LDEF results on the space application of metal matrix composites

Over 200 graphite/aluminum and graphite/magnesium composites were flown on the leading and trailing edges of LDEF on the Advanced Composites Experiment. The performance of these composites was evaluated by performing scanning electron microscopy and x-ray photoelectron spectroscopy of exposed surfaces, optical microscopy of cross sections, and on-orbit and postflight thermal expansion measurements. Graphite/aluminum and graphite/magnesium were found to be superior to graphite/polymer matrix composites in that they are inherently resistant to atomic oxygen and are less susceptible to thermal cycling induced microcracking. The surface foils on graphite/aluminum and graphite/magnesium protect the graphite fibers from atomic oxygen and from impact damage from small micrometeoroid or space debris particles. However, the surface foils were found to be susceptible to thermal fatigue cracking arising from contamination embrittlement, surface oxidation, or stress risers. Thus, the experiment reinforced requirements for carefully protecting these composites from prelaunch oxidation or corrosion, avoiding spacecraft contamination, and designing composite structures to minimize stress concentrations. On-orbit strain measurements demonstrated the importance of through-thickness thermal conductivity in composites to minimize thermal distortions arising from thermal gradients. Because of the high thermal conductivity of aluminum, thermal distortions were greatly reduced in the LDEF thermal environment for graphite/aluminum as compared to graphite/magnesium and graphite/polymer composites. The thermal expansion behavior of graphite/aluminum and graphite/magnesium was stabilized by on-orbit thermal cycling in the same manner as observed in laboratory tests.

Steckel, Gary L.↗
NASA NTRS1992

Tension fracture of laminates for transport fuselage. Part 1: Material screening

Transport fuselage structures are designed to contain pressure following a large penetrating damage event. Application of composites to fuselage structures requires a data base and supporting analysis on tension damage tolerance. Tests with 430 fracture specimens were used to accomplish the following: (1) identify critical material and laminate variables affecting notch sensitivity, (2) evaluate composite failure criteria, and (3) recommend a screening test method. Variables studied included fiber type, matrix toughness, lamination manufacturing process, and intraply hybridization. The laminates found to have the lowest notch sensitivity were manufactured using automated tow placement. This suggests a possible relationship between the stress distribution and repeatable levels of material inhomogeneity that are larger than found in traditional tape laminates. Laminates with the highest notch sensitivity consisted of toughened matrix materials that were resistant to a splitting phenomena that reduces stress concentrations in load bearing plies. Parameters for conventional fracture criteria were found to increase with the crack length of the smallest notch sizes studied. Most materials and laminate combinations followed less than a square root singularity for the largest crack sizes studied. Specimen geometry, notch type, and notch size were evaluated in developing a screening test procedure. Results indicate that a range of notch sizes must be tested to determine notch sensitivity.

Walker, T. H.↗
NASA NTRS1994

Graphing techniques for materials laboratory using Excel

Engineering technology curricula stress hands on training and laboratory practices in most of the technical courses. Laboratory reports should include analytical as well as graphical evaluation of experimental data. Experience shows that many students neither have the mathematical background nor the expertise for graphing. This paper briefly describes the procedure and data obtained from a number of experiments such as spring rate, stress concentration, endurance limit, and column buckling for a variety of materials. Then with a brief introduction to Microsoft Excel the author explains the techniques used for linear regression and logarithmic graphing.

Kundu, Nikhil K.↗
NASA NTRS1992

Modeling of Thermal Barrier Coatings

The project examined the effectiveness of studying the creep behavior of thermal barrier coating system through the use of a general purpose, large strain finite element program, NIKE2D. Constitutive models implemented in this code were applied to simulate thermal-elastic and creep behavior. Four separate ceramic-bond coat interface geometries were examined in combination with a variety of constitutive models and material properties. The reason for focusing attention on the ceramic-bond coat interface is that prior studies have shown that cracking occurs in the ceramic near interface features which act as stress concentration points. The model conditions examined include: (1) two bond coat coefficient of thermal expansion curves; (2) the creep coefficient and creep exponent of the bond coat for steady state creep; (3) the interface geometry; and (4) the material model employed to represent the bond coat, ceramic, and superalloy base.

Ferguson, B. L.↗