SEARCH · Search NASA

Results for “delamination damage”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 451 records · Page 25

All sources NASA NTRS DOE OSTI

NASA NTRS2020

Stochastic Simulation of Mudcrack Damage Formation in an Environmental Barrier Coating

The FEAMAC/CARES program, which integrates finite element analysis (FEA) with the MAC/GMC (Micromechanics Analysis Code with Generalized Method of Cells) and the CARES/Life (Ceramics Analysis and Reliability Evaluation of Structures / Life Prediction) programs, was used to simulate the formation of mudcracks during the cooling of a multilayered environmental barrier coating (EBC) deposited on a silicon carbide substrate. FEAMAC/CARES combines the MAC/GMC multiscale micromechanics analysis capability (primarily developed for composite materials) with the CARES/Life probabilistic multiaxial failure criteria (developed for brittle ceramic materials) and Abaqus (Dassault Systèmes) FEA. In this report, elastic modulus reduction of randomly damaged finite elements was used to represent discrete cracking events. The use of many small-sized low-aspect-ratio elements enabled the formation of crack boundaries, leading to development of mudcrack-patterned damage. Finite element models of a disk-shaped three-dimensional specimen and a twodimensional model of a through-the-thickness cross section subjected to progressive cooling from 1,300 °C to an ambient temperature of 23 °C were made. Mudcrack damage in the coating resulted from the buildup of residual tensile stresses between the individual material constituents because of thermal expansion mismatches between coating layers and the substrate. A two-parameter Weibull distribution characterized the coating layer stochastic strength response and allowed the effect of the Weibull modulus on the formation of damage and crack segmentation lengths to be studied. The spontaneous initiation of cracking and crack coalescence resulted in progressively smaller mudcrack cells as cooling progressed, consistent with a fractal-behaved fracture pattern. Other failure modes such as delamination, and possibly spallation, could also be reproduced. The physical basis assumed and the heuristic approach employed, which involves a simple stochastic cellular automaton methodology to approximate the crack growth process, are described. The results ultimately show that a selforganizing mudcrack formation can derive from a Weibull distribution that is used to describe the stochastic strength response of the bulk brittle ceramic material layers of an EBC.

Nemeth, Noel N.↗

NASA NTRS1991

Impact Damage In Carbon/Epoxy And Carbon/PEEK Composites

Report describes results of drop-weight impact testing of specimens of carbon-fiber/epoxy and carbon-fiber/polyetheretherketone (PEEK) composite materials. Panels made of these materials assembled into lightweight, strong, stiff structures useful in automobiles, aircraft, sporting goods, and many other products. PEEK specimens showed less delamination than epoxy specimens at given impact energy.

Nettles, A. T.↗

NASA NTRS2005

Damage Accumulation and Failure of Plasma-Sprayed Thermal Barrier Coatings under Thermal Gradient Cyclic Conditions

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future engine higher fuel efficiency and lower emission goals. A fundamental understanding of the sintering and thermal cycling induced delamination of thermal barrier coating systems under engine-like heat flux conditions will potentially help to improve the coating temperature capability. In this study, a test approach is established to emphasize the real-time monitoring and assessment of the coating thermal conductivity, which can initially increase under the steady-state high temperature thermal gradient test due to coating sintering, and later decrease under the thermal gradient cyclic test due to coating cracking and delamination. Thermal conductivity prediction models have been established for a ZrO2-(7- 8wt%)Y2O3 model coating system in terms of heat flux, time, and testing temperatures. The coating delamination accumulation is then assessed based on the observed thermal conductivity response under the combined steady-state and cyclic thermal gradient tests. The coating thermal gradient cycling associated delaminations and failure mechanisms under simulated engine heat-flux conditions will be discussed in conjunction with the coating sintering and fracture testing results.

Zhu, Dongming↗

DOE OSTI2022

Direct recycling and remanufacturing of anode scraps

With the rapid expansion of Li-ion battery production, significant amounts of electrode scraps that need to be recycled are being produced during cell manufacturing. Anode scrap that comprises critical materials such as graphite and valuable Cu should be recycled and reintegrated into the battery supply chain. This study reports a simple yet efficient water-based recovery process for delaminating anode films from Cu foils through the intercalation of water between the hydrophilic Cu foil and hydrophobic anode coating. Because of the absence of harsh chemicals, the recovered anode films and Cu foils are battery grade and free of damage in terms of physical and chemical properties. This study also demonstrates the reprocessing of those anode films into a new anode that exhibits electrochemical performance similar to that of the pristine anode. We report this environmentally friendly and cost-effective separation technique allows battery manufacturers to directly recycle and reuse their electrode scraps safely and effectively on-site.

25 ENERGY STORAGE↗

NASA NTRS1987

Damage growth in composite laminates with interleaves

The influence of placing interleaves between fiber reinforced plies in multilayered composite laminates is investigated. The geometry of the composite is idealized as two dimensional, isotropic, linearly elastic media made of a damaged layer bonded between two half planes and separated by thin interleaves of low extensional and shear moduli. The damage in the layer is taken in the form of a symmetric crack perpendicular to the interface and may extend up to the interface. The case of an H-shaped crack in the form of a broken layer with delamination along the interface is also analyzed. The interleaves are modeled as distributed shear and tension springs. Fourier integral transform techniques are used to develop solutions in terms of singular integral equations. An asymptotic analysis of the integral equations based on Muskhelishvili's techniques reveals logarithmically singular axial stresses in the half plane at the crack tips for the broken layer. For the H shaped crack, similar singularities are found to exist in the axial stresses at the interface crack tips in the layer and the half plane. The solution of the equations is found numerically for the stresses and displacements by using the Hadamard's concept of direct differentiation of Cauchy integrals as well as Gaussian integration techniques.

Goree, James G.↗

NASA NTRS2008

Reliability of PWB Microvias for High Density Package Assembly

High density PWB (printed wiring board) with microvia technology is required for implementation of high density and high I/O area array packages (AAP). COTS (commercial off-the-shelf) AAP packaging technologies in high reliability versions with 1.27 mm pitch are now being considered for use in a number of NASA systems including Space Shuttle and Mars Rovers. NASA functional system designs are requiring more and more dense AAP packages and board space, which makes board microvia technology very attractive for effectively routing a large number of package inputs/outputs. However, the reliability of the fine feature microvias including via in pads is unknown for space applications. Understanding process and QA (quality assurance) indicators for reliability are important for low risk insertion of these newly available packages and PWBs. This paper presents literature search as well as test results for a high density board subjected to various thermal cycle and reflow profiles representative of tin-lead and lead-free solder reflow. Microvias sizes ranged from two to six mil with and without filling. Daisy chain microvias monitored during the test and PWBs were cross-sectioned to determine failure and locations. Optical and SEM photographs as well as resistance changes during cycling and Tg/Td (glass transition/decomposition temperature) characterisations are presented.

fill via↗

NASA NTRS2011

Wavenumber Imaging For Damage Detection and Measurement

This paper presents a method for analyzing ultrasonic wavefield data using the Continuous Wavelet Transform (CWT) applied in the spatial domain. Unlike data obtained by sparse arrays of transducers, full wavefield data contains information local to the structure and can be used to obtain more detailed measurements of damage type, location, size, etc. By calculating the CWT of the wavefield in the spatial domain, the wavenumber spectrum is determined for the inspected locations. Because wavenumber is affected by the local geometry and material properties of the structure through which Lamb waves propagate, the wavenumber spectrum can be analyzed to assess the location, severity, and size of damage. The technique is first applied to experimental wavefield data obtained using a laser Doppler vibrometer and automated positioning stage. The out-of-plane velocity along the length of a composite stringer was measured to detect the presence of delaminations within the composite overwrap. Next, simulated corrosion is detected and measured within an aluminum plate using the two dimensional CWT. The experimental results show the usefulness of the technique for vehicle structure inspection applications.

Rogge, Matthew D.↗

NASA NTRSDate not supplied

TPSAS-NF1676L-25778-DND

Testing required to design and certify aircraft structures has increased dramatically with the growth in use of composite materials, and the development time and cost have become an issue as industry looks towards the next generation of aircraft. To help address this challenge, NASA has formed an industry-spanning consortium with the goal of cutting by 30% today's 10-year timeline for developing and certifying composite aircraft structures. This goal is to be achieved by infusing leading edge, physics-based tools to improve the prediction of the response and failure of composite aerospace structures. The plan for the public-private partnership of NASA, the FAA, airframe manufacturers, aircraft engine manufacturers, and several universities is to conduct joint research under the five-year Advanced Composites Program (ACP). The emphasis of the ACP project is the development of damage prediction and non-destructive inspection methods capabilities that are sufficiently reliable to enable a reduction in the element and subcomponent testing necessary for design and certification. ACP also is expected to create rapid design tools to speed preliminary design and improve safety and performance. A critical element of this research concerns the residual strength of postbuckled stiffened panels with impact damage. This presentation will discuss different aspects of ongoing research on the prediction of structural collapse due to skin/stiffener separation. In particular, the presentation will examine issues that must be addressed in the analysis, such as R-curve toughening, delamination migration, bridging, as well as some unexpected effects of ply orientation.

Carlos G Davila↗

DOE OSTI2023

Guidelines for predicting stress in cemented doublets undergoing temperature change

This work explores quick predictive methods for calculating potentially risky stresses and deflections in cemented doublets experiencing temperature change that agree well with finite element analysis. There are three failure modes of interest: cohesive failure of the adhesive, delamination (surface bond failure or debonding), and glass fracture. Adhesive theory, confirmed by finite element analysis, predicts stress singularities that complicate interpretation of the stress calculations. The presence of a stress singularity indicates the breakdown of linear elastic assumptions, but damage initiation and stress singularities are related. The authors find that geometry details near a bond edge can exacerbate or minimize damage initiation and stress concentrations. Because the interpretation of the stress results is complicated, the authors investigated predicted stresses in doublets that have been successfully tested between -40 and 85 °C. This study found that the product (ΔT ∙ Δα) should be less than 189 ppm, where ΔT is the temperature excursion and Δα is the difference in glass coefficient of thermal expansion. If the product (ΔT ∙ Δα) is equal to or greater than 189 ppm, further analysis and testing is warranted. But the authors also show that the fabrication process can significantly influence stress failure, particularly with large diameter doublets.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Guidelines for predicting stress in cemented doublets undergoing temperature change

This work explores quick predictive methods for calculating potentially risky stresses and deflections in cemented doublets experiencing temperature change that agree well with finite element analysis. There are three failure modes of interest: cohesive failure of the adhesive, delamination (surface bond failure or debonding), and glass fracture. Adhesive theory, confirmed by finite element analysis, predicts stress singularities that complicate interpretation of the stress calculations. The presence of a stress singularity indicates the breakdown of linear elastic assumptions, but damage initiation and stress singularities are related. The authors find that geometry details near a bond edge can exacerbate or minimize damage initiation and stress concentrations. Because the interpretation of the stress results is complicated, the authors investigated predicted stresses in doublets that have been successfully tested between -40 and 85 °C. This study found that the product (∆T ∙ ∆α) should be less than 189 ppm, where ∆T is the temperature excursion and ∆α is the difference in glass coefficient of thermal expansion. If the product (∆T ∙ ∆α) is equal to or greater than 189 ppm, further analysis and testing is warranted. But the authors also show that the fabrication process can significantly influence stress failure, particularly with large diameter doublets

42 ENGINEERING↗

NASA NTRS2013

NDE Evidence for the Damage Arrestment Performance of PRSEUS Composite Cube During High-Pressure Load Test

As an approach to light-weight, cost-effective and manufacturable structures required to enable the hybrid wing body aircraft, The Boeing Company, Inc. and NASA have developed the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. A PRSEUS pressure cube was developed as a risk reduction test article to examine a new integral cap joint concept as part of a building block approach for technology development of the PRSEUS concept. The overall specimen strength exceeded the 18.4 psi load requirement as testing resulted in the cube reaching a final pressure load of around 48 psi prior to catastrophic failure. The cube pressure test verified that the joints and structure were capable of sustaining the required loads, and represented the first testing of joined PRSEUS structure. This paper will address the damage arrestment performance of the stitched PRSEUS structure. Following catastrophic failure of the cube, ultrasonic pulse-echo inspection found that the localized damage, surrounding a barely-visible impact damage site, did not change noticeably between just after impact and catastrophic failure of the cube, and did not play a role in the catastrophic failure event. Ultrasonic inspection of the remaining intact cube panels presented three basic types of indications: delaminations between laminae parallel to the face sheets, lying between face sheet and tear strap layers, or between tear strap and flange layers; delaminations above the noodles of stringers, frames or integral caps, lying within face sheet or tear strap layers; and delaminations between the laminae in the inner fillets of the integral caps, where pulloff stresses were expected to be highest. Delaminations of all three types were predominantly contained by the first row of stitches encountered. For the small fraction of delaminations extending beyond the first row of stitches, all were contained by the second stitch row.

Johnston, Patrick H.↗

NASA NTRS1982

Recognizing defects in carbon-fiber reinforced plastics

The damage tolerance of structures made of carbon-fiber-reinforced plastic is tested under various loads. Test laminate (73/1/1, 24/9/1, 1465 A) specimens of thickness 1.5-3.2 mm with various defects were subjected to static and dynamic loads. Special attention was given to delamination, and ultrasonic C-scans were made on the specimens. It was shown that cracks from even small defects are detected with great accuracy. The same probes were also X rayed; defects that could not be detected under ordinary X rays were bored and studied under vacuum by a contrast technique. The nondestructive ultrasonic and X ray tests were controlled by partially destructive tests, and good agreement was observed.

Schuetze, R.↗

NASA NTRS1998

Thermographic Qualification of Graphite/Epoxy Instrumentation Racks

A nondestructive evaluation method is desired for ensuring the 'as manufactured' and 'post service' quality of graphite/epoxy instrumentation rack shells. The damage tolerance and geometry of the racks dictate that the evaluation method be capable of identifying defects, as small as 0.25 inch 2 in area, over large acreage regions, tight compound radii and thickness transition zones. The primary defects of interest include voids, inclusions, delaminations and porosity. The potential for an infrared thermographic inspection to replace ultrasonic testing, for qualifying the racks as 'defect free' is under investigation. The inspection process is validated by evaluating defect standard panels built to the same specifications as the racks, except for the insertion of artificial fabricated defects. The artificial defects are designed to match those which are most prevalent in the actual instrumentation racks. A target defect area of 0.0625 inch 2 (a square with 0.25 inch on a side) was chosen for the defect standard panels to ensure the ability to find all defects of the critical (0.25 inch squared) size.

Walker, James L.↗

NASA NTRS2016

The Behavior of a Stitched Composite Large-Scale Multi-Bay Pressure Box

NASA has created the Environmentally Responsible Aviation (ERA) Project to develop technologies to reduce impact of aviation on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe to enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company have worked together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composite structures. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together and designed to maintain residual load-carrying capabilities under a variety of damage scenarios. With the PRSEUS concept, through-the-thickness stitches are applied through dry fabric prior to resin infusion, and replace fasteners throughout each integral panel. Through-the-thickness reinforcement at discontinuities, such as along flange edges, has been shown to suppress delamination and turn cracks, which expands the design space and leads to lighter designs. The pultruded rod provides stiffening away from the more vulnerable skin surface and improves bending stiffness. A series of building block tests were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. The final step in the building block series of tests is an 80%-scale pressure box representing a portion of the center section of a Hybrid Wing Body (HWB) transport aircraft. The testing of this test article under maneuver and internal pressure loading conditions is the subject of this paper. The experimental evaluation of this article, along with the other building block tests and the accompanying analyses, has demonstrated the viability of a PRSEUS center body for the HWB vehicle. Additionally, much of the development effort is also applicable to traditional tube-and-wing aircraft, advanced aircraft configurations, and other structures where weight and through-the-thickness strength are design considerations.

Jegley, Dawn C.↗

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 NTRS2016

The EST Model for Predicting Progressive Damage and Failure of Open Hole Bending Specimens

Progressive damage and failure in open hole composite laminate coupons subjected to flexural loading is modeled using Enhanced Schapery Theory (EST). Previous studies have demonstrated that EST can accurately predict the strength of open hole coupons under remote tensile and compressive loading states. This homogenized modeling approach uses single composite shell elements to represent the entire laminate in the thickness direction and significantly reduces computational cost. Therefore, when delaminations are not of concern or are active in the post-peak regime, the version of EST presented here is a good engineering tool for predicting deformation response. Standard coupon level tests provides all the input data needed for the model and they are interpreted in conjunction with finite element (FE) based simulations. Open hole bending test results of three different IM7/8552 carbon fiber composite layups agree well with EST predictions. The model is able to accurately capture the curvature change and deformation localization in the specimen at and during the post catastrophic load drop event.

damage↗

NASA NTRSDate not supplied

Exploration Helmet Permanent Anti-fog Study

For the current Extravehicular Mobility Unit (EMU) spacesuit, an astronaut applies an anti-fog solution to the interior of the helmet bubble before each EVA. However, the anti-fog solution has been reported to cause eye discomfort during at least seven EMU EVAs when the anti-fog solution contacted the crew member’s eyes. During STS-100, astronaut Chris Hadfield reported the eye irritation temporarily blinded him during his spacewalk. In addition, the wipe on anti-fog solution is a consumable that needs to be accounted for and a supply launched for missions. To solve this, the Exploration EMU (xEMU) pressure bubble investigated using a permanent anti-fog coating during Design Verification and Test (DVT) human in the loop (HITL) events. Chosen for previous use in Constellation Space Suit develop, HTAF-601, a water based permanent anti-fog solution, was tested. However, major issues have arisen with further HITL testing with the coating. Cleaning the helmet has been a challenge to avoid damaging the permanent anti-fog coating. NASA has completed a set of different methods for cleaning the anti-fog to try to document a preferred method. It was found isopropyl alcohol (IPA) cannot be used to clean the interior of the helmet because it will strip and delaminate the permanent anti-fog coating. Even with using a very gentle cleaning method of flushing with distilled or DI water and dabbing at facial oils, the permanent anti-fog starts to delaminate consistently after 50 hours manned pressurized time (MPT). Finally, the HTAF-601 coating is being discontinued by the vendor. Due to these issues, further investigation is being completed evaluating two solvent based anti-fog solutions: Exxene’s HCF-100 and FSI’s Visgard 106-94. Each coating will be evaluated on polycarbonate samples for application consistency, steam cycles (mimicking breath cycles), cleaning durability, haze, and light transmission. This study will determine if either coating is a viable option to pursue as a permanent anti-fog for spacesuit helmet applications.

spacesuit↗

NASA NTRS1990

Effect of interleaves on fracture of laminated composites. I - Analysis. II - Solution and results

The effect of interleaves placed between the fiber-reinforced plies of multilayered composite laminates is investigated analytically, with the composite approximated by linearly elastic isotropic media consisting of half-planes separated from a finite-width layer by thin interleaves of low extensional and shear moduli. Integral equations are derived which describe the effect of interleaves on damage growth. Numerical solutions are then developed which are based on Gaussian integration techniques and Hadamard's concept of differentiation of Cauchy integrals. Critical stresses and displacements are calculated to investigate the influence of relative elastic properties and geometry of the interleafed composite on interface debonding, extent and suppression and delamination, and stress relieving in the undamaged plies.

Kaw, A. K.↗