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NASA NTRS2002

The Use of Doublers in Delamination Toughness Testing

In this paper, the data reduction equations for common delamination toughness tests are rederived for use with specimens which have bonded doublers. The common toughness tests considered here are the double cantilever beam (DCB) for mode I toughness; the end notch flexure (3ENF) and 4 point ENF (4ENF) for mode II toughness; and the mixed mode bending (MMB) test for testing under combined mode I and mode II loading. Because the addition of the doublers changes the bending stiffness of the specimens, these data reduction equations may need to be corrected. Doublers were added to the delamination test specimens to solve a premature failure problem. Delamination toughness is normally tested using a beam with an imbedded insert so that one end of the specimen is split into two arms. If the specimen is too thin, or if the toughness of the material is too high, an arm of the specimen may fail in bending before the delamination grows. When this occurs, the toughness of the material cannot be determined. To delay the bending failure so that delamination growth occurs, doubler plates were bonded to both top and bottom surfaces of the specimen. A doubler parameter, beta, which describes how much the use of doubler plates changed the ratio of full thickness to delaminated bending stiffnesses, was defined. When changes to the data reduction equations were required, the changes were minor when written in terms of the beta parameter. The doubler plate technique was demonstrated by measuring the mixed-mode fracture toughness of a carbon-carbon composite using test specimens which would otherwise have failed before delamination growth occurred. The doubler plate technique may solve several problems that can be encountered when testing delamination fracture toughness.

Reeder, James R.↗

NASA NTRS2003

Effect of Elevated Temperature and Loading Rate on Delamination Fracture Toughness

The effects of temperature and loading rate on delamination growth were studied. The delamination fracture toughness of IM7/K3B was measured at 149 C, 177 C, and 204 C. At each temperature the tests were performed with a variety of loading rates so that the delamination initiated over the range of time from 0.5 sec to 24 hrs. The double cantilever beam (DCB) test was used to measure fracture toughness. The results showed that the delamination resistance is a complicated function of both time and temperature with the effect of temperature either increasing or decreasing the fracture toughness depending on the time scale. The results also showed that the fracture toughness changed by as much as a factor of three as the time scale changed over the five orders of magnitude tested.

Reeder, J. R.↗

NASA NTRS2001

A Shell/3D Modeling Technique for the Analyses of Delaminated Composite Laminates

A shell/3D modeling technique was developed for which a local three-dimensional solid finite element model is used only in the immediate vicinity of the delamination front. The goal was to combine the accuracy of the full three-dimensional solution with the computational efficiency of a plate or shell finite element model. Multi-point constraints provided a kinematically compatible interface between the local three-dimensional model and the global structural model which has been meshed with plate or shell finite elements. Double Cantilever Beam (DCB), End Notched Flexure (ENF), and Single Leg Bending (SLB) specimens were modeled using the shell/3D technique to study the feasibility for pure mode I (DCB), mode II (ENF) and mixed mode I/II (SLB) cases. Mixed mode strain energy release rate distributions were computed across the width of the specimens using the virtual crack closure technique. Specimens with a unidirectional layup and with a multidirectional layup where the delamination is located between two non-zero degree plies were simulated. For a local three-dimensional model, extending to a minimum of about three specimen thicknesses on either side of the delamination front, the results were in good agreement with mixed mode strain energy release rates obtained from computations where the entire specimen had been modeled with solid elements. For large built-up composite structures modeled with plate elements, the shell/3D modeling technique offers a great potential for reducing the model size, since only a relatively small section in the vicinity of the delamination front needs to be modeled with solid elements.

Krueger, Ronald↗

NASA NTRS1999

A Shell/3D Modeling Technique for Delaminations in Composite Laminates

A shell/3D modeling technique was developed for which a local solid finite element model is used only in the immediate vicinity of the delamination front. The goal was to combine the accuracy of the full three-dimensional solution with the computational efficiency of a plate or shell finite element model. Multi-point constraints provide a kinematically compatible interface between the local 3D model and the global structural model which has been meshed with plate or shell finite elements. For simple double cantilever beam (DCB), end notched flexure (ENF), and single leg bending (SLB) specimens, mixed mode energy release rate distributions were computed across the width from nonlinear finite element analyses using the virtual crack closure technique. The analyses served to test the accuracy of the shell/3D technique for the pure mode I case (DCB), mode II case (ENF) and a mixed mode I/II case (SLB). Specimens with a unidirectional layup where the delamination is located between two 0 plies, as well as a multidirectional layup where the delamination is located between two non-zero degree plies, were simulated. For a local 3D model extending to a minimum of about three specimen thicknesses in front of and behind the delamination front, the results were in good agreement with mixed mode strain energy release rates obtained from computations where the entire specimen had been modeled with solid elements. For large built-up composite structures modeled with plate elements, the shell/3D modeling technique offers a great potential, since only a relatively small section in the vicinity of the delamination front needs to be modeled with solid elements.

Krueger, Ronald↗

NASA NTRS2000

Dry Ribbon for Heated Head Automated Fiber Placement

Ply-by-ply in situ processes involving automated heated head deposition are being developed for fabrication of high performance, high temperature composite structures from low volatile content polymer matrices. This technology requires (1) dry carbon fiber towpreg, (2) consolidation of towpreg to quality, placement-grade unidirectional ribbon or tape, and (3) rapid, in situ, accurate, ply-by-ply robotic placement and consolidation of this material to fabricate a composite structure. In this study, the physical properties of a candidate thermoplastic ribbon, PIXA/IM7, were evaluated and screened for suitability in robotic placement. Specifically, towpreg was prepared from PIXA powder. Various conditions (temperatures) were used to convert the powder-coated towpreg to ribbons with varying degrees of processability. Ribbon within preset specifications was fabricated at 3 temperatures: 390, 400 and 410 C. Ribbon was also produced out-of-spec by purposely overheating the material to a processing temperature of 450 C. Automated placement equipment at Cincinnati Milacron and NASA Langley was used to fabricate laminates from these experimental ribbons. Ribbons were placed at 405 and 450 C by both sets of equipment. Double cantilever beam and wedge peel tests were used to determine the quality of the laminates and, especially, the interlaminar bond formed during the placement process. Ribbon made under conditions expected to be non-optimal (overheated) resulted in poor placeability and composites with weak interlaminar bond strengths, regardless of placement conditions. Ribbon made under conditions expected to be ideal showed good processability and produced well-consolidated laminates. Results were consistent from machine to machine and demonstrated the importance of ribbon quality in heated-head placement of dry material forms. Preliminary screening criteria for the development and evaluation of ribbon from new matrix materials were validated.

Hulcher, A. Bruce↗

NASA NTRS2003

Mechanical characteristics of rat vibrissae: resonant frequencies and damping in isolated whiskers and in the awake behaving animal

We investigated the natural resonance properties and damping characteristics of rat macrovibrissae (whiskers). Isolated whiskers rigidly fixed at the base showed first-mode resonance peaks between 27 and 260 Hz, principally depending on whisker length. These experimentally measured resonant frequencies were matched using a theoretical model of the whisker as a conical cantilever beam, with Young's modulus as the only free parameter. The best estimate for Young's modulus was approximately 3-4 GPa. Results of both vibration and impulse experiments showed that the whiskers are strongly damped, with damping ratios between 0.11 and 0.17. In the behaving animal, whiskers that deflected past an object were observed to resonate but were damped significantly more than isolated whiskers. The time course of damping varied depending on the individual whisker and the phase of the whisking cycle, which suggests that the rat may modulate biomechanical parameters that affect damping. No resonances were observed for whiskers that did not contact the object or during free whisking in air. Finally, whiskers on the same side of the face were sometimes observed to move in opposite directions over the full duration of a whisk. We discuss the potential roles of resonance during natural exploratory behavior and specifically suggest that resonant oscillations may be important in the rat's tactile detection of object boundaries.

Vibration↗

NASA NTRS2004

Development of a Low Data Event Timer for Monitoring an Advancing Crack in Fracture

Monitoring the crack position and velocity in a fracture specimen can be difficult and laborious. In addition, the data storage requirements can be considerable depending upon the testing conditions. A low data event timer was developed to alleviate these problems. The test apparatus was applied to cantilever beams bonded with a structural epoxy and tested under different conditions such as stable to unstable transitions and different temperature extremes. The results indicate that the approach eliminates problems associated with other types of crack measurement and greatly simplifies the measuring process.

Macon, D. J.↗

NASA NTRS1990

Mixed-Mode Bending Method for Delamination Testing

A mixed mode delamination test procedure was developed combining double cantilever beam (DCB) mode I loading and end-notch fixture (ENF) mode II loading on a split unidirectional laminate. By loading with a lever, a single applied load simultaneously produces mode I and mode II bending loads on the specimen. This mixed-mode bending (MMB) test was analyzed using both finite-element procedures and beam theory to calculate the mode I and mode II components of strain-energy release rate G(sub I) and G(sub II), respectively. A wide range of G(sub I)/G(sub II) ratios can be produced by varying the load position on the lever. As the delamination extended, the G(sub I)/G(sub II) ratios varied by less than 5%. Beam theory equations agreed closely with the finite-element results and provide a basis for selection of G(sub I)/G(sub II) test ratios and a basis for computing the mode I and mode II components of measured delamination toughness. The MMB test was demonstrated using AS4/PEEK (APC2) unidirectional laminates. The MMB test introduced in this paper is rather simple and is believed to offer several advantages over most current mixed-mode test.

Reeder, James R.↗

NASA NTRS2004

Penalty-Based Interface Technology for Prediction of Delamination Growth in Laminated Structures

An effective interface element technology has been developed for connecting and simulating crack growth between independently modeled finite element subdomains (e.g., composite plies). This method has been developed using penalty constraints and allows coupling of finite element models whose nodes do not necessarily coincide along their common interface. Additionally, the present formulation leads to a computational approach that is very efficient and completely compatible with existing commercial software. The present interface element has been implemented in the commercial finite element code ABAQUS as a User Element Subroutine (UEL), making it easy to test the approach for a wide range of problems. The interface element technology has been formulated to simulate delamination growth in composite laminates. Thanks to its special features, the interface element approach makes it possible to release portions of the interface surface whose length is smaller than that of the finite elements. In addition, the penalty parameter can vary within the interface element, allowing the damage model to be applied to a desired fraction of the interface between the two meshes. Results for double cantilever beam DCB, end-loaded split (ELS) and fixed-ratio mixed mode (FRMM) specimens are presented. These results are compared to measured data to assess the ability of the present damage model to simulate crack growth.

Averill, Ronald C.↗

NASA NTRS2004

Thermal-Stress Control of Microshutter Arrays in Cryogenic Applications for the James Webb Space Telescope

We report on methods to minimize thermally-induced deformation in a MEMS-based reconfigurable aperture. The device is an enabling component of the Near-Infrared Spectrometer, a principle instrument on NASA's James Webb Space Telescope. The Microshutter Array consists of 384 x 175 individually addressable shutters which can be magnetically rotated 90 deg into the plane of the array and electrostatically latched open. Each shutter is a 100 x 200 micron rectangular membrane suspended by a small neck region and torsion flexure. The primary materials in the shutter are a 5000A Si3N4 layer for mechanical rigidity, 2000A Al for opacity and electrostatic latching, and 2800A CoFe for magnetic actuation. This multi-layer stack presents a challenge due to the operating temperatures required for the device: both room temperature (300K) and cryogenic temperature (35K). Thermal expansion of the materials causes the shutters to bow out of plane excessively, which can prevent actuation of the shutters, cause damage to portions of the array, and allow light leakage around closed shutters. Here we present our investigation of several methods to prevent microshutter bowing including deposition of additional materials on the shutters to create a symmetrical layer stack and replacing the current stack with low-coefficient of thermal expansion materials. Using shutter-size suspended cantilever beams as a rapid-development test bed, we have reduced out-of-plane bowing between 300K and 35K to 10% or better. We are currently applying these results to microshutter arrays to develop shutters that remain flat from room temperature to cryogenic temperature while retaining the required mechanical, optical, and magnetic properties.

Kelly, Daniel P.↗

NASA NTRS1998

Drag Force Anemometer Used in Supersonic Flow

To measure the drag on a flat cantilever beam exposed transversely to a flow field, the drag force anemometer (beam probe) uses strain gauges attached on opposite sides of the base of the beam. This is in contrast to the hot wire anemometer, which depends for its operation on the variation of the convective heat transfer coefficient with velocity. The beam probe retains the high-frequency response (up to 100 kHz) of the hot wire anemometer, but it is more rugged, uses simpler electronics, is relatively easy to calibrate, is inherently temperature compensated, and can be used in supersonic flow. The output of the probe is proportional to the velocity head of the flow, 1/2 rho u(exp 2) (where rho is the fluid density and u is the fluid velocity). By adding a static pressure tap and a thermocouple to measure total temperature, one can determine the Mach number, static temperature, density, and velocity of the flow.

Fralick, Gustave C.↗

NASA NTRS2005

Ka-Band, MEMS Switched Line Phase Shifters Implemented in Finite Ground Coplanar Waveguide

Ka-band MEMS switched line phase shifters implemented in finite ground coplanar waveguide are described in this paper. The phase shifters are constructed of single-pole double-throw (SPDT) switches with additional reference and phase offset transmission line lengths. The one- and two-bit phase shifters are fabricated on high resistivity (HR) silicon with a dielectric constant, Epsilon(sub T) = 11.7 and a substrate thickness, t = 500microns. The switching architectures integrated within the phase shifters consist of MEMS switches that are doubly anchored cantilever beam capacitive switches with additional high inductive sections (MEMS LC device). The SPDT switch is composed of a T-junction with a MEMS LC device at each output port. The one-bit phase shifter described in this paper has an insertion loss (IL) and return loss (RL) of 0.9 dB and 30 dB while the two-bit described has an IL and RL of 1.8 dB and 30 dB respectively. The one-bit phase shifter's designed offset phase is 22.5deg and actual measured phase shift is 21.8deg. The two-bit phase shifter's designed offset phase is 22.5deg, 45deg, and 67.5deg and the actual measured phase shifts are 21.4deg, 44.2deg, and 65.8deg, respectively.

Scardelletti, Maximilian C.↗

NASA NTRS2006

Multiscale Analysis of Delamination of Carbon Fiber-Epoxy Laminates with Carbon Nanotubes

A multi-scale analysis is presented to parametrically describe the Mode I delamination of a carbon fiber/epoxy laminate. In the midplane of the laminate, carbon nanotubes are included for the purposes of selectively enhancing the fracture toughness of the laminate. To analyze carbon fiber epoxy carbon nanotube laminate, the multi-scale methodology presented here links a series of parameterizations taken at various length scales ranging from the atomistic through the micromechanical to the structural level. At the atomistic scale molecular dynamics simulations are performed in conjunction with an equivalent continuum approach to develop constitutive properties for representative volume elements of the molecular structure of components of the laminate. The molecular-level constitutive results are then used in the Mori-Tanaka micromechanics to develop bulk properties for the epoxy-carbon nanotube matrix system. In order to demonstrate a possible application of this multi-scale methodology, a double cantilever beam specimen is modeled. An existing analysis is employed which uses discrete springs to model the fiber bridging affect during delamination propagation. In the absence of empirical data or a damage mechanics model describing the effect of CNTs on fracture toughness, several tractions laws are postulated, linking CNT volume fraction to fiber bridging in a DCB specimen. Results from this demonstration are presented in terms of DCB specimen load-displacement responses.

Riddick, Jaret C.↗

NASA NTRS2006

Effect of Embedded Piezoelectric Sensors on Fracture Toughness and Fatigue Resistance of Composite Laminates Under Mode I Loading

Double-cantilevered beam (DCB) specimens of a glass/epoxy composite material with embedded piezoelectric sensors were tested both statically and under fatigue loading to determine the effect of the embedded material on the Mode I fracture toughness and fatigue resistance compared to baseline data without the embedded elements. A material known as LaRC-Macrofiber Composite (LaRC-MFC (TradeMark)), or MFC, was embedded at the midplane of the specimen during the layup. Specimens were manufactured with the embedded MFC material either at the loaded end of the specimen to simulate an initial delamination; or with the MFC material located at the delaminating interface, with a Teflon film at the loaded end to simulate an initial delamination. There were three types of specimens with the embedded material at the delaminating interface: co-cured with no added adhesive; cured with a paste adhesive applied to the embedded element; or cured with a film adhesive added to the embedded material. Tests were conducted with the sensors in both the passive and active states. Results were compared to baseline data for the same material without embedded elements. Interlaminar fracture toughness values (G(sub Ic)) for the passive condition showed little change when the MFC was at the insert end. Passive results varied when the MFC was at the delaminating interface. For the co-cured case and with the paste adhesive, G(sub Ic) decreased compared to the baseline toughness, whereas, for the film adhesive case, G(sub Ic) was significantly greater than the baseline toughness, but the failure was always catastrophic. When the MFC was in the active state, G(sub Ic) was generally lower compared to the passive results. Fatigue tests showed little effect of the embedded material whether it was active or passive compared to baseline values.

Murri, Gretchen B.↗

NASA NTRS2006

Influence of Finite Element Software on Energy Release Rates Computed Using the Virtual Crack Closure Technique

Strain energy release rates were computed along straight delamination fronts of Double Cantilever Beam, End-Notched Flexure and Single Leg Bending specimens using the Virtual Crack Closure Technique (VCCT). Th e results were based on finite element analyses using ABAQUS# and ANSYS# and were calculated from the finite element results using the same post-processing routine to assure a consistent procedure. Mixed-mode strain energy release rates obtained from post-processing finite elem ent results were in good agreement for all element types used and all specimens modeled. Compared to previous studies, the models made of s olid twenty-node hexahedral elements and solid eight-node incompatible mode elements yielded excellent results. For both codes, models made of standard brick elements and elements with reduced integration did not correctly capture the distribution of the energy release rate acr oss the width of the specimens for the models chosen. The results suggested that element types with similar formulation yield matching results independent of the finite element software used. For comparison, m ixed-mode strain energy release rates were also calculated within ABAQUS#/Standard using the VCCT for ABAQUS# add on. For all specimens mod eled, mixed-mode strain energy release rates obtained from ABAQUS# finite element results using post-processing were almost identical to re sults calculated using the VCCT for ABAQUS# add on.

Krueger, Ronald↗

NASA NTRS2006

Using the Climbing Drum Peel (CDP) Test to Obtain a G(sub IC) value for Core/Facesheet Bonds

A method of measuring the Mode I fracture toughness of core/facesheet bonds in sandwich Structures is desired, particularly with the widespread use of models that need this data as input. This study examined if a critical strain energy release rate, G(sub IC), can be obtained from the climbing drum peel (CDP) test. The CDP test is relatively simple to perform and does not rely on measuring small crack lengths such as required by the double cantilever beam (DCB) test. Simple energy methods were used to calculate G(sub IC) from CDP test data on composite facesheets bonded to a honeycomb core. Facesheet thicknesses from 2 to 5 plies were tested to examine the upper and lower bounds on facesheet thickness requirements. Results from the study suggest that the CDP test, with certain provisions, can be used to find the GIG value of a core/facesheet bond.

Nettles, A. T.↗

NASA NTRS2006

Measuring Core/Facesheet Bond Toughness in Honeycomb Sandwich Structures

This study examines two test methods to evaluate the peel toughness of the skin to core debond of sandwich panels. The methods tested were the climbing drum (CD) peel test and the double cantilever beam (DCB) test. While the CD peel test is only intended for qualitative measurements, it is shown in this study that qualitative measurements can be performed and compare well with DCB test data. It is also shown that artificially stiffening the facesheets of a DCB specimen can cause the test to behave more like a flatwise tensile test than a peel test.

Nettles, A. T.↗

NASA NTRS2007

An Approach for Assessing Delamination Propagation Capabilities in Commercial Finite Element Codes

An approach for assessing the delamination propagation capabilities in commercial finite element codes is presented and demonstrated for one code. For this investigation, the Double Cantilever Beam (DCB) specimen and the Single Leg Bending (SLB) specimen were chosen for full three-dimensional finite element simulations. First, benchmark results were created for both specimens. Second, starting from an initially straight front, the delamination was allowed to propagate. Good agreement between the load-displacement relationship obtained from the propagation analysis results and the benchmark results could be achieved by selecting the appropriate input parameters. Selecting the appropriate input parameters, however, was not straightforward and often required an iterative procedure. Qualitatively, the delamination front computed for the DCB specimen did not take the shape of a curved front as expected. However, the analysis of the SLB specimen yielded a curved front as may be expected from the distribution of the energy release rate and the failure index across the width of the specimen. Overall, the results are encouraging but further assessment on a structural level is required.

Krueger, Ronald↗