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NASA NTRS1991

Long discontinuous fiber composite structure: Forming and structural mechanics

Cost effective composite structure has motivated the investigation of several new approaches to develop composite structure from innovative material forms. Among the promising new approaches is the conversion of planar sheet to components of complex curvature through sheet forming or stretch forming. In both cases, the potential for material stretch in the fiber direction appears to offer a clear advantage in formability over continuous fiber systems. In the present study, the authors have established a framework which allows the simulation of the anisotropic mechanisms of deformation of long discontinuous fiber laminates wherein the matrix phase is a viscous fluid. The initial study focuses upon the establishment of micromechanics models for prediction of the effective anisotropic viscosities of the oriented fiber assembly in a viscous matrix. Next, the developed constitutive relation is employed through an analogy with incompressible elasticity to exercise the finite element technique for determination of local fiber orientation and laminate thickness after forming. Results are presented for the stretch bending of a curved beam from an arbitrary composite laminate and the bulging of a clamped sheet. Structural analyses are conducted to determine the effect of microstructure on the performance of curved beams manufactured from long discontinuous fiber composites. For the purposes of this study, several curved beams with ideal and non-ideal microstructures are compared for response under pure bending. Material parameters are determined from a separate microstructural analysis.

Pipes, R. B.↗

NASA NTRS1991

Structural reliability methods: Code development status

The Probabilistic Structures Analysis Method (PSAM) program integrates state of the art probabilistic algorithms with structural analysis methods in order to quantify the behavior of Space Shuttle Main Engine structures subject to uncertain loadings, boundary conditions, material parameters, and geometric conditions. An advanced, efficient probabilistic structural analysis software program, NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) was developed as a deliverable. NESSUS contains a number of integrated software components to perform probabilistic analysis of complex structures. A nonlinear finite element module NESSUS/FEM is used to model the structure and obtain structural sensitivities. Some of the capabilities of NESSUS/FEM are shown. A Fast Probability Integration module NESSUS/FPI estimates the probability given the structural sensitivities. A driver module, PFEM, couples the FEM and FPI. NESSUS, version 5.0, addresses component reliability, resistance, and risk.

Millwater, Harry R.↗

NASA NTRS1993

Thermomechanical buckling of multilayered composite panels with cutouts

A study is made of the thermomechanical buckling of flat unstiffened composite panels with central circular cutouts. The panels are subjected to combined temperature changes and applied edge loading (or edge displacements). The analysis is based on a first-order shear deformation plate theory. A mixed formulation is used with the fundamental unknowns consisting of the generalized displacements and the stress resultants of the plate. Both the stability boundary and the sensitivity coefficients are evaluated. The sensitivity coefficients measure the sensitivity of the buckling response to variations in the different lamination and material parameters of the panel. Numerical results are presented showing the effects of the variations in the hole diameter, laminate stacking sequence, fiber orientation, and aspect ratio of the panel on the thermomechanical buckling response and its sensitivity coefficients.

Noor, Ahmed K.↗

NASA NTRS1993

Thermal-mechanical behavior of high precision composite mirrors

Composite mirror panels were designed, constructed, analyzed, and tested in the framework of a NASA precision segmented reflector task. The deformations of the reflector surface during the exposure to space enviroments were predicted using a finite element model. The composite mirror panels have graphite-epoxy or graphite-cyanate facesheets, separated by an aluminum or a composite honeycomb core. It is pointed out that in order to carry out detailed modeling of composite mirrors with high accuracy, it is necessary to have temperature dependent properties of the materials involved and the type and magnitude of manufacturing errors and material nonuniformities. The structural modeling and analysis efforts addressed the impact of key design and materials parameters on the performance of mirrors.

Kuo, C. P.↗

NASA NTRS1992

Experimental, physical and numerical modeling of lunar regolith and lunar regolith structures

An extensive series of laboratory strength and deformation experiments have been performed on a lunar regolith simulant. Results of these experiments are compared to results from experiments on real lunar regolith from the Apollo and Luna missions to illustrate the suitability of this material in capturing the engineering properties lunar regolith. In addition, these results are used to calibrate a constitutive model used to describe its stress-strain behavior. This model, in conjunction with numerical analysis techniques, is used to predict the response i.e. material parameters) of lunar simulant under 1/6-g and low confining stress conditions. These tools are also used to predict the displacement response of a lunar soil embankment structure used to cover a first generation human habitat module, which might be used to accommodate the first astronauts revisiting the moon. These predictions are compared to physical models of this structure, which are tested in a geotechnical centrifuge in order to satisfy scaling relationships between prototype and model.

Perkins, Steven W.↗

NASA NTRS1994

A hydrostatic stress-dependent anisotropic model of viscoplasticity

A hydrostatic stress-dependent, anisotropic model of viscoplasticity is formulated as an extension of Bodner's model. This represents a further extension of the isotropic Bodner model over that made to anisotropy by Robinson and MitiKavuma. Account is made of the inelastic deformation that can occur in metallic composites under hydrostatic stress. A procedure for determining the material parameters is identified that is virtually identical to the established characterization procedure for the original Bodner model. Characterization can be achieved using longitudinal/transverse tensile and shear tests and hydrostatic stress tests; alternatively, four off-axis tensile tests can be used. Conditions for a yield stress minimum under off-axis tension are discussed. The model is applied to a W/Cu composite; characterization is made using off-axis tensile data generated at NASA Lewis Research Center (LeRC).

Robinson, D. N.↗

NASA NTRS1994

Optimization of Residual Stresses in MMC's Using Compensating/Compliant Interfacial Layers. Part 2: OPTCOMP User's Guide

A user's guide for the computer program OPTCOMP is presented in this report. This program provides a capability to optimize the fabrication or service-induced residual stresses in uni-directional metal matrix composites subjected to combined thermo-mechanical axisymmetric loading using compensating or compliant layers at the fiber/matrix interface. The user specifies the architecture and the initial material parameters of the interfacial region, which can be either elastic or elastoplastic, and defines the design variables, together with the objective function, the associated constraints and the loading history through a user-friendly data input interface. The optimization procedure is based on an efficient solution methodology for the elastoplastic response of an arbitrarily layered multiple concentric cylinder model that is coupled to the commercial optimization package DOT. The solution methodology for the arbitrarily layered cylinder is based on the local-global stiffness matrix formulation and Mendelson's iterative technique of successive elastic solutions developed for elastoplastic boundary-value problems. The optimization algorithm employed in DOT is based on the method of feasible directions.

Pindera, Marek-Jerzy↗

NASA NTRS1994

Computational predictive methods for fracture and fatigue

The damage-tolerant design philosophy as used by aircraft industries enables aircraft components and aircraft structures to operate safely with minor damage, small cracks, and flaws. Maintenance and inspection procedures insure that damages developed during service remain below design values. When damage is found, repairs or design modifications are implemented and flight is resumed. Design and redesign guidelines, such as military specifications MIL-A-83444, have successfully reduced the incidence of damage and cracks. However, fatigue cracks continue to appear in aircraft well before the design life has expired. The F16 airplane, for instance, developed small cracks in the engine mount, wing support, bulk heads, the fuselage upper skin, the fuel shelf joints, and along the upper wings. Some cracks were found after 600 hours of the 8000 hour design service life and design modifications were required. Tests on the F16 plane showed that the design loading conditions were close to the predicted loading conditions. Improvements to analytic methods for predicting fatigue crack growth adjacent to holes, when multiple damage sites are present, and in corrosive environments would result in more cost-effective designs, fewer repairs, and fewer redesigns. The overall objective of the research described in this paper is to develop, verify, and extend the computational efficiency of analysis procedures necessary for damage tolerant design. This paper describes an elastic/plastic fracture method and an associated fatigue analysis method for damage tolerant design. Both methods are unique in that material parameters such as fracture toughness, R-curve data, and fatigue constants are not required. The methods are implemented with a general-purpose finite element package. Several proof-of-concept examples are given. With further development, the methods could be extended for analysis of multi-site damage, creep-fatigue, and corrosion fatigue problems.

Cordes, J.↗

NASA NTRS1994

TEXCAD: Textile Composite Analysis for Design. Version 1.0: User's manual

The Textile Composite Analysis for Design (TEXCAD) code provides the materials/design engineer with a user-friendly desktop computer (IBM PC compatible or Apple Macintosh) tool for the analysis of a wide variety of fabric reinforced woven and braided composites. It can be used to calculate overall thermal and mechanical properties along with engineering estimates of damage progression and strength. TEXCAD also calculates laminate properties for stacked, oriented fabric constructions. It discretely models the yarn centerline paths within the textile repeating unit cell (RUC) by assuming sinusoidal undulations at yarn cross-over points and uses a yarn discretization scheme (which subdivides each yarn not smaller, piecewise straight yarn slices) together with a 3-D stress averaging procedure to compute overall stiffness properties. In the calculations for strength, it uses a curved beam-on-elastic foundation model for yarn undulating regions together with an incremental approach in which stiffness properties for the failed yarn slices are reduced based on the predicted yarn slice failure mode. Nonlinear shear effects and nonlinear geometric effects can be simulated. Input to TEXCAD consists of: (1) materials parameters like impregnated yarn and resin properties such moduli, Poisson's ratios, coefficients of thermal expansion, nonlinear parameters, axial failure strains and in-plane failure stresses; and (2) fabric parameters like yarn sizes, braid angle, yarn packing density, filament diameter and overall fiber volume fraction. Output consists of overall thermoelastic constants, yarn slice strains/stresses, yarn slice failure history, in-plane stress-strain response and ultimate failure strength. Strength can be computed under the combined action of thermal and mechanical loading (tension, compression and shear).

Naik, Rajiv A.↗

NASA NTRS1994

Resistance of Silicon Nitride Turbine Components to Erosion and Hot Corrosion/oxidation Attack

Silicon nitride turbine components are under intensive development by AlliedSignal to enable a new generation of higher power density auxiliary power systems. In order to be viable in the intended applications, silicon nitride turbine airfoils must be designed for survival in aggressive oxidizing combustion gas environments. Erosive and corrosive damage to ceramic airfoils from ingested sand and sea salt must be avoided. Recent engine test experience demonstrated that NT154 silicon nitride turbine vanes have exceptional resistance to sand erosion, relative to superalloys used in production engines. Similarly, NT154 silicon nitride has excellent resistance to oxidation in the temperature range of interest - up to 1400 C. Hot corrosion attack of superalloy gas turbine components is well documented. While hot corrosion from ingested sea salt will attack silicon nitride substantially less than the superalloys being replaced in initial engine applications, this degradation has the potential to limit component lives in advanced engine applications. Hot corrosion adversely affects the strength of silicon nitride in the 850 to 1300 C range. Since unacceptable reductions in strength must be rapidly identified and avoided, AlliedSignal and the NASA Lewis Research Center have pioneered the development of an environmental life prediction model for silicon nitride turbine components. Strength retention in flexure specimens following 1 to 3300 hour exposures to high temperature oxidation and hot corrosion has been measured and used to calibrate the life prediction model. Predicted component life is dependent upon engine design (stress, temperature, pressure, fuel/air ratio, gas velocity, and inlet air filtration), mission usage (fuel sulfur content, location (salt in air), and times at duty cycle power points), and material parameters. Preliminary analyses indicate that the hot corrosion resistance of NT154 silicon nitride is adequate for AlliedSignal's initial engine applications. Protective coatings and/or inlet air filtration may be required to achieve required ceramic component lives in more aggressive environments.

Strangmen, Thomas E.↗

NASA NTRS1995

Finite element buckling and postbuckling solutions for multilayered composite panels

A study is made of the buckling and postbuckling responses of flat, unstiffened composite panels subjected to various combinations of mechanical and thermal loads. The analysis is based on a first-order shear deformation von Karman-type plate theory. A mixed formulation is used with the fundamental unknowns consisting of the strain components, stress resultants and the generalized displacements of the plate. The stability boundary, postbuckling response and the sensitivity coefficients are evaluated. The sensitivity coefficients measure the sensitivity of the buckling and postbuckling responses to variations in the different lamination and material parameters of the panel. Numerical results are presented for both solid panels and panels with central circular cutouts. The results show the effects of the variations in the fiber orientation angels, aspect ratio of the panel, and the hole diameter (for panels with cutouts) on the stability boundary, postbuckling response and sensitivity coefficients.

Noor, Ahmed K.↗

NASA NTRS1995

Thermomechanical postbuckling of multilayered composite panels with cutouts

The results of a study of the detailed thermomechanical postbuckling response characteristics of flat unstiffened composite panels with central circular cutouts are presented. The panels are subjected to combined temperature changes and applied edge loading (or edge displacements). The analysis is based on a first-order shear deformation plate theory. A mixed formulation is used with the fundamental unknowns consisting of the generalized displacements and the stress resultants of the plate. The postbuckling displacements, transverse shear stresses, transverse shear strain energy density, and their sensitivity coefficients are evaluated. The sensitivity coefficients measure the sensitivity of the post-buckling response to variations in the different lamination and material parameters of the panel. Numerical results are presented showing the effects of the variations in the hole diameter, laminate stacking sequence, fiber orientation, and aspect ratio of the panel on the thermomechanical postbuckling response and its sensitivity to changes in panel parameters.

Noor, Ahmed K.↗

NASA NTRS1995

Sensitivity analysis for the dynamic response of viscoplastic shells of revolution

A computational procedure is presented for evaluating the sensitivity coefficients of the dynamic axisymmetric response of viscoplastic shells of revolution. The analytical formulation is based on Reissner's large deformation shell theory with the effects of transverse shear deformation, rotatory inertia and moments turning around the normal to the middle surface included. The material model is chosen to be isothermal viscoplasticity, and an associated flow rule is used with a von Mises effective stress. A mixed formulation is used with the fundamental unknowns consisting of six stress resultants, three generalized displacements and three velocity components. Spatial discretization is performed using finite elements, with discontinuous stress resultants across element interfaces. The temporal integration is performed by using an explicit central difference scheme (leap-frog method) with an implicit constitutive update. The sensitivity coefficients are evaluated using a direct differentiation approach. Numerical results are presented for a spherical cap subjected to step loading, and a circular plate subjected to impulsive loading. The sensitivity coefficients are generated by evaluating the derivatives of the response quantities with respect to thickness, mass density, Young's modulus, and two of the material parameters characterizing the viscoplastic response. Time histories of the response and sensitivity coefficients are presented, along with spatial distributions of these quantities at selected times.

Kulkarni, Makarand↗

NASA NTRS1995

Assessment of computational models for thermoelectroelastic multilayered plates

A study is made of the accuracy of the steady-state (static) thermoelectroelastic response of multilayered hybrid composite plates predicted by five modeling approaches, based on two-dimensional plate theories. The plates consist of a combination of fiber-reinforced and piezothermoelastic layers. The standard of comparison is taken to be the exact three-dimensional thermoelectroelastic solutions, and the quantities compared include gross response characteristics (e.g., strain energy components, and average through-the-thickness displacements); detailed, through-the-thickness distributions of displacements and stresses; and sensitivity coefficients of the response quantities (derivatives of the response quantities with respect to material parameters of the plate). The modeling approaches considered include first-order theory; third-order theory; discrete-layer theory (with piecewise linear variation of the in-plane displacements, temperature and electric potential, in the thickness direction); and two predictor-corrector procedures.

Tang, Yvette T.↗

NASA NTRS1994

Thermomechanical buckling of multilayered composite panels with cutouts

THERMOMECHANICAL BUCKLING↗

NASA NTRS1994

Transverse shear stresses and their sensitivity coefficients in multilayered composite panels

A computational procedure is presented for the accurate determination of transverse shear stresses and their sensitivity coefficients in flat multilayered composite panels subjected to mechanical and thermal loads. The sensitivity coefficients measure the sensitivity of the transverse shear stresses to variations in the different lamination and material parameters of the panel. The panel is discretized by using either a three-field mixed finite element model based on a two-dimensional first- order shear deformation plate theory or a two-field degenerate solid element with each of the displacement components having a linear variation throughout the thickness of the laminate. The evaluation of transverse shear stresses can be conveniently divided into two phases. The first phase consists of using a superconvergent recovery technique for evaluating the in-plane stresses in the different layers. In the second phase, the transverse shear stresses are evaluated by using piecewise integration, in the thickness direction, of the three-dimensional equilibrium equations. The same procedure is used for evaluating the sensitivity coefficients of the transverse shear stresses. The effectiveness of the computational procedure is demonstrated by means of numerical examples of multilayered cross-ply panels subjected to transverse loading, uniform temperature change, and uniform temperature gradient through the thickness of the panel. In each case the standard of the comparison is taken to be the exact solution of the three dimensional thermoelasticity equations of the panel.

Noor, Ahmed K.↗

NASA NTRS1994

Thermomechanical buckling of multilayered composite panels with cutouts

Noor, Ahmed K.↗

NASA NTRS1995

Parasitic current collection by PASP Plus solar arrays

Solar cells at potentials positive with respect to a surrounding plasma collect electrons. Current is collected by the exposed high voltage surfaces: the interconnects and the sides of the solar cells. This current is a drain on the array power that can be significant for high-power arrays. In addition, this current influences the current balance that determines the floating potential of the spacecraft. One of the objectives of the Air Force (PL/GPS) PASP Plus (Photovoltaic Array Space Power Plus Diagnostics) experiment is an improved understanding fo parasitic current collection. We have done computer modeling of parasitic current collection and have examined current collection flight data from the first year of operations. Prior to the flight we did computer modeling to improve our understanding of the physical processes that control parasitic current collection. At high potentials, the current rapidly rises due to a phenomenon called snapover. Under snapover conditions, the equilibrium potential distribution across the dielectric surface is such that part of the area is at potentials greater than the first crossover of the secondary yield curve. Therefore, each incident electron generates more than one secondary electron. The net effect is that the high potential area and the collecting area increase. We did two-dimensional calculations for the various geometries to be flown. The calculations span the space of anticipated plasma conditions, applied potential, and material parameters. We used the calculations and early flight data to develop an analytic formula for the dependence of the current on the primary problem variables. The analytic formula was incorporated into the EPSAT computer code. EPSAT allows us to easily extend the results to other conditions. PASP Plus is the principal experiment integrated onto the Advanced Photovoltaic and Electronics Experiments (APEX) satellite bus. The experiment is testing twelve different solar array designs. Parasitic current collection is being measured for eight of the designs under various operational and environment conditions. We examined the current collected as a function of the various parameters for the six non-concentrator designs. The results are similar to those obtained in previous experiments and predicted by the calculations. We are using the flight data to validate the analytic formula developed. The formula can be used to quantify the parasitic current collected. Anticipating the parasitic current value allows the spacecraft designer to include this interaction when developing the design.

Davis, Victoria Ann↗