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At least 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

In-Situ Nondestructive Evaluation of Kevlar(Registered Trademark)and Carbon Fiber Reinforced Composite Micromechanics for Improved Composite Overwrapped Pressure Vessel Health Monitoring

NASA has been faced with recertification and life extension issues for epoxy-impregnated Kevlar 49 (K/Ep) and carbon (C/Ep) composite overwrapped pressure vessels (COPVs) used in various systems on the Space Shuttle and International Space Station, respectively. Each COPV has varying criticality, damage and repair histories, time at pressure, and pressure cycles. COPVs are of particular concern due to the insidious and catastrophic burst-before-leak failure mode caused by stress rupture (SR) of the composite overwrap. SR life has been defined [1] as the minimum time during which the composite maintains structural integrity considering the combined effects of stress level(s), time at stress level(s), and associated environment. SR has none of the features of predictability associated with metal pressure vessels, such as crack geometry, growth rate and size, or other features that lend themselves to nondestructive evaluation (NDE). In essence, the variability or surprise factor associated with SR cannot be eliminated. C/Ep COPVs are also susceptible to impact damage that can lead to reduced burst pressure even when the amount of damage to the COPV is below the visual detection threshold [2], thus necessitating implementation of a mechanical damage control plan [1]. Last, COPVs can also fail prematurely due to material or design noncompliance. In each case (SR, impact or noncompliance), out-of-family behavior is expected leading to a higher probability of failure at a given stress, hence, greater uncertainty in performance. For these reasons, NASA has been actively engaged in research to develop NDE methods that can be used during post-manufacture qualification, in-service inspection, and in-situ structural health monitoring. Acoustic emission (AE) is one of the more promising NDE techniques for detecting and monitoring, in real-time, the strain energy release and corresponding stress-wave propagation produced by actively growing flaws and defects in composite materials [3,4,5,6,7,8]. To gain further insight into the mechanisms responsible for composite rupture, broadband modal acoustic emission analysis was used. Also, since AE data reduction proved to be very time consuming, specialized data reduction software was written to automate the process.

Waller, Jess↗
NASA NTRS2012

Effects of Subscale Size and Shape on Global Energy Dissipation in a Multiscale Model of a Fiber-Reinforced Composite Exhibiting Post-Peak Strain Softening Using Abaqus and FEAMAC

A mesh objective crack band model is implemented in the generalized method of cells (GMC) micromechanics model to predict failure of a composite repeating unit cell (RUC). The micromechanics calculations are achieved using the MAC/GMC core engine within the ImMAC suite of micromechanics codes, developed at the NASA Glenn Research Center. The microscale RUC is linked to a macroscale Abaqus/Standard finite element model using the FEAMAC multiscale framework (included in the ImMAC suite). The effects of the relationship between the characteristic length of the finite element and the size of the microscale RUC on the total energy dissipation of the multiscale model are investigated. A simple 2-D composite square subjected to uniaxial tension is used to demonstrate the effects of scaling the dimensions of the RUC such that the length of the sides of the RUC are equal to the characteristic length of the finite element. These results are compared to simulations where the size of the RUC is fixed, independent of the element size. Simulations are carried out for a variety of mesh densities and element shapes, including square and triangular. Results indicate that a consistent size and shape must be used to yield preserve energy dissipation across the scales.

Pineda, Evan, J.↗
NASA NTRS2013

Supersonic Retropulsion Surface Preparation of Carbon Fiber Reinforced Epoxy Composites for Adhesive Bonding

Surface preparation is widely recognized as a key step to producing robust and predictable bonds in a precise and reproducible manner. Standard surface preparation techniques, including grit blasting, manual abrasion, and peel ply, can lack precision and reproducibility, which can lead to variation in surface properties and subsequent bonding performance. The use of a laser to ablate composite surface resin can provide an efficient, precise, and reproducible means of preparing composite surfaces for adhesive bonding. Advantages include elimination of physical waste (i.e., grit media and sacrificial peel ply layers that ultimately require disposal), reduction in process variability due to increased precision (e.g. increased reproducibility), and automation of surface preparation, all of which improve reliability and process control. This paper describes a Nd:YAG laser surface preparation technique for composite substrates and the mechanical performance and failure modes of bonded laminates thus prepared. Additionally, bonded specimens were aged in a hot, wet environment for approximately one year and subsequently mechanically tested. The results of a one year hygrothermal aging study will be presented.

Palmieri, Frank L.↗
NASA NTRS2016

Model-Based Fatigue Prognosis of Fiber-Reinforced Laminates Exhibiting Concurrent Damage Mechanisms

Prognostics of large composite structures is a topic of increasing interest in the field of structural health monitoring for aerospace, civil, and mechanical systems. Along with recent advancements in real-time structural health data acquisition and processing for damage detection and characterization, model-based stochastic methods for life prediction are showing promising results in the literature. Among various model-based approaches, particle-filtering algorithms are particularly capable in coping with uncertainties associated with the process. These include uncertainties about information on the damage extent and the inherent uncertainties of the damage propagation process. Some efforts have shown successful applications of particle filtering-based frameworks for predicting the matrix crack evolution and structural stiffness degradation caused by repetitive fatigue loads. Effects of other damage modes such as delamination, however, are not incorporated in these works. It is well established that delamination and matrix cracks not only co-exist in most laminate structures during the fatigue degradation process but also affect each other's progression. Furthermore, delamination significantly alters the stress-state in the laminates and accelerates the material degradation leading to catastrophic failure. Therefore, the work presented herein proposes a particle filtering-based framework for predicting a structure's remaining useful life with consideration of multiple co-existing damage-mechanisms. The framework uses an energy-based model from the composite modeling literature. The multiple damage-mode model has been shown to suitably estimate the energy release rate of cross-ply laminates as affected by matrix cracks and delamination modes. The model is also able to estimate the reduction in stiffness of the damaged laminate. This information is then used in the algorithms for life prediction capabilities. First, a brief summary of the energy-based damage model is provided. Then, the paper describes how the model is embedded within the prognostic framework and how the prognostics performance is assessed using observations from run-to-failure experiments

Prognostics↗
NASA NTRS1993

Nondestructive Characterization of the Elastic Constants of Fiber Reinforced Composites

Composite structural components may be subjected to a variety of defects resulting in a sharp reduction in their load carrying capacity or even catastrophic failure...A nondestructive method based on ultrasonics has recently been developed for the quantitative evaluation of composite structural components during service...In this paper the method is applied to determine the stiffness constants of unidirectional graphite/epoxy materials.

composites↗
NASA NTRS1991

A comparison of fiber effects on polymer matrix composite oxidation

A number of thermo-oxidative stability studies addressing the effects of fiber reinforcement on composite thermal stability and influence of geometry on the results of aging studies were performed at NASA-Lewis. The information presented herein, a compilation of some results from these studies, shows the influence of the reinforcement fibers on the oxidative degradation of various PMR-15 composites. Reinforcement of graphite and ceramics were studied and three composite oxidation mechanisms were observed. One was a dominant attack of the reinforcement fiber, the second was the aggressive oxidation of the matrix material, and the third was interfacial degradation.

Bowles, Kenneth J.↗
NASA NTRS1979

Computer design synthesis of a below knee-Syme prosthesis

A detailed design synthesis analysis of the BK Syme prosthesis is provided, to determine the socket's cutout orientation size and shape, cutout fillet shape, socket wall thickness distribution and the reinforced fiber distribution in the socket wall, for a minimally stressed structurally safe lightweight prosthesis. For analysis purposes, the most adverse socket loading is obtained at the push-off stage of gait; this loading is idealized as an axial in-plane loading on the bottom edge of the circular cylindrical socket shell whose top edge is considered fixed. Finite element stress analysis of the socket shell (with uniform and graded wall thickness) are performed for various orientations of the cutout and for various types of corner fillets. A lateral cutout with a streamline fillet is recommended. The wall material (i.e., thickness) distribution is determined so as to minimize the stresses, while ensuring that the wall material's stress limits are not exceeded. For such a maximally stressed lightweight socket shell, the panels in the neighborhood of the cutout are checked to ensure that they do not buckle under their acquired stresses. A fiber-reinforced laminated composite socket shell is also analyzed in order to recommend optimum variables in orientations and densities of reinforcing fibers.

Elangovan, P. T.↗
NASA NTRS1998

Development and Characterization of SiC)/ MoSi2-Si3N4(p) Hybrid Composites

Intermetallic compound MoSi2 has long been known as a high temperature material that has excellent oxidation resistance and electrical/thermal conductivity. Also its low cost, high melting point (2023 C), relatively low density (6.2 g/cu cm versus 9 g/cu cm for current engine materials), and ease of machining, make it an attractive structural material. However, the use of MoSi2 has been hindered due to its poor toughness at low temperatures, poor creep resistance at high temperatures, and accelerated oxidation (also known as 'pest' oxidation) at temperatures between approximately 450 and 550 C. Continuous fiber reinforcing is very effective means of improving both toughness and strength. Unfortunately, MoSi2 has a relatively high coefficient of thermal expansion (CTE) compared to potential reinforcing fibers such as SiC. The large CTE mismatch between the fiber and the matrix resulted in severe matrix cracking during thermal cycling. Addition of about 30 to 50 vol % of Si3N4 particulate to MoSi2 improved resistance to low temperature accelerated oxidation by forming a Si2ON2 protective scale and thereby eliminating catastrophic 'pest failure'. The Si3N4 addition also improved the high temperature creep strength by nearly five orders of magnitude, doubled the room temperature toughness and significantly lowered the CTE of the MoSi2 and eliminated matrix cracking in SCS-6 reinforced composites even after thermal cycling. The SCS-6 fiber reinforcement improved the room temperature fracture toughness by seven times and impact resistance by five times. The composite exhibited excellent strength and toughness improvement up to 1400 C. More recently, tape casting was adopted as the preferred processing of MoSi2-base composites for improved fiber spacing, ability to use small diameter fibers, and for lower cost. Good strength and toughness values were also obtained with fine diameter Hi-Nicalon tow fibers. This hybrid composite remains competitive with ceramic matrix composites as a replacement for Ni-base superalloys in aircraft engine applications.

Hebsur, Mohan G.↗
NASA NTRS1985

Fracture surface analysis in composite and titanium bonding

To understand the mechanical properties of fiber-reinforced composite materials, it is necessary to understand the mechanical properties of the matrix materials and of the reinforcing fibers. Another factor that can affect the mechanical properties of a composite material is the interaction between the fiber and the matrix. In general, composites with strong fiber matrix bonding will give higher modulus, lower toughness composites. Composites with weak bonding will have a lower modulus and more ductility. The situation becomes a bit more complex when all possibilities are examined. To be considered are the following: the properties of the surface layer on the fiber, the interactive forces between polymer and matrix, the surface roughness and porosity of the fiber, and the morphology of the matrix polymer at the fiber surface. In practice, the surface of the fibers is treated to enhance the mechanical properties of a composite. These treatments include anodization, acid etching, high temperature oxidation, and plasma oxidation, to name a few. The goal is to be able to predict the surface properties of carbon fibers treated in various ways, and then to relate surface properties to fiber matrix bonding.

Devilbiss, T. A.↗
NASA NTRS1992

Effect of braze processing on the microstructure and mechanical properties of SCS-6/beta21S titanium matrix composites

An investigation is conducted of the effects of braze processing on the microstructure and tensile properties of SiC fiber-reinforced Ti-15Mo-2.7Nb-3Al-0.25Si-matrix composite (TMC) laminates; the brazing alloy was the commercial Ti-15Cu-15Ni, in both its conventional and metglass forms. Tensile tests conducted at room temperature, 1200 F, and 1500 F showed that the braze processes (1) had little effect on tensile properties, and (2) appeared to degrade neither the reinforcing fibers not the fiber/matrix interfacial bondline.

Hoffman, Eric K.↗
NASA NTRS1996

Kinetics of Cyclic Oxidation and Cracking and Finite Element Analysis of MA956 and Sapphire/MA956 Composite System

Sapphire fiber-reinforced MA956 composites hold promise for significant weight savings and increased high-temperature structural capability, as compared to unreinforced MA956. As part of an overall assessment of the high-temperature characteristics of this material system, cyclic oxidation behavior was studied at 1093 C and 1204 C. Initially, both sets of coupons exhibited parabolic oxidation kinetics. Later, monolithic MA956 exhibited spallation and a linear weight loss, whereas the composite showed a linear weight gain without spallation. Weight loss of the monolithic MA956 resulted from the linking of a multiplicity of randomly oriented and closely spaced surface cracks that facilitated ready spallation. By contrast, cracking of the composite's oxide layer was nonintersecting and aligned nominally parallel with the orientation of the subsurface reinforcing fibers. Oxidative lifetime of monolithic MA956 was projected from the observed oxidation kinetics. Linear elastic, finite element continuum, and micromechanics analyses were performed on coupons of the monolithic and composite materials. Results of the analyses qualitatively agreed well with the observed oxide cracking and spallation behavior of both the MA956 and the Sapphire/MA956 composite coupons.

Lee, Kang N.↗
NASA NTRS2003

Liner-less Tanks for Space Application - Design and Manufacturing Considerations

Composite pressure vessels, used extensively for gas and fuel containment in space vehicles, are generally constructed with a metallic liner, while the fiber reinforcement carries the major portion of the pressure-induced load. The design is dominated by the liner s low strain at yield since the reinforcing fibers cannot operate at their potential load-bearing capability without resorting to pre-stressing (or autofrettaging). An ultra high-efficiency pressure vessel, which operates at the optimum strain capability of the fibers, can be potentially achieved with a liner-less construction. This paper discusses the design and manufacturing challenges to be overcome in the development of such a pressure vessel. These include: (1) gas/liquid containment and permeation, (2) design and structural analysis, and (3) manufacturing process development. The paper also presents the development and validation tests on a liner-less pressure vessel developed by Kaiser Compositek Inc. (KCI). It should be noted that KCI s liner-less tank exhibits a highly controlled leak-before-burst mode. This feature results in a structure having the highest level of safety.

Jones, Brian H.↗
NASA NTRS2016

Temperature Dependence of Electrical Resistance of Woven Melt-Infiltrated SiCf/SiC Ceramic Matrix Composites

Recent studies have successfully shown the use of electrical resistance (ER)measurements to monitor room temperature damage accumulation in SiC fiber reinforced SiC matrix composites (SiCf/SiC) Ceramic Matrix Composites (CMCs). In order to determine the feasibility of resistance monitoring at elevated temperatures, the present work investigates the temperature dependent electrical response of various MI (Melt Infiltrated)-CVI (Chemical Vapor Infiltrated) SiC/SiC composites containing Hi-Nicalon Type S, Tyranno ZMI and SA reinforcing fibers. Test were conducted using a commercially available isothermal testing apparatus as well as a novel, laser-based heating approach developed to more accurately simulate thermomechanical testing of CMCs. Secondly, a post-test inspection technique is demonstrated to show the effect of high-temperature exposure on electrical properties. Analysis was performed to determine the respective contribution of the fiber and matrix to the overall composite conductivity at elevated temperatures. It was concluded that because the silicon-rich matrix material dominates the electrical response at high temperature, ER monitoring would continue to be a feasible method for monitoring stress dependent matrix cracking of melt-infiltrated SiC/SiC composites under high temperature mechanical testing conditions. Finally, the effect of thermal gradients generated during localized heating of tensile coupons on overall electrical response of the composite is determined.

Ceramic Matrix Composites↗
NASA NTRS1972

Fatigue of composites

The failure mechanisms in the fatigue of composite materials are analyzed in terms of the requirements for designing fatigue-critical composite structures. Fiber reinforced polymers, fiber reinforced metals, fatigue of composite structures, and composite design considerations are discussed. It is concluded that composite materials offer the engineer the opportunity for tailoring stiffness in different directions for designing dynamic components.

Salkind, M. J.↗
NASA NTRS1980

Compression panel studies for supersonic cruise vehicles

Results of analytical and experimental studies are summarized for titanium, boron fiber reinforced aluminum matrix composite, Borsic fiber reinforced aluminum matrix composite, and titanium sheathed Borsic fiber reinforced aluminum matrix composite stiffened panels. The results indicate that stiffened panels with continuous joints (i.e., brazed, diffusion bonded or adhesive bonded joints) are more structurally efficient than geometrically similar panels with discrete joints (i.e., spotwelded or bolted joints). In addition, results for various types of fiber reinforced aluminum matrix stiffened panels indicate that titanium sheathed Borsic fiber reinforced aluminum matrix composite panels are the most structurally efficient. Analytical results are also presented for graphite fiber reinforced polyimide matrix composite stiffened panels and superplastically formed and diffusion bonded titanium sandwich panels.

Mcwithey, R. R.↗
NASA NTRS1961

Development of Ceramic Fibers for Reinforcement in Composite Materials

Refinements of the vertical arc fiberizing apparatus resulted in its ability to fiberize very different refractory glasses having wide ranges of properties. Although the apparatus, was originally designed as a laboratory research tool for the evaluation of many compositions daily, up to one quarter pound of fibers of a single composition could be produced in an 8-hour day. Fibers up to six and a half feet long were produced with the apparatus. Studies were conducted of two methods of fiberizing refractory glasses requiring rapid freezing from the melt. The first method consisted of fiberizing droplets of molten glass passing through an annular nozzle. The second method consisted of reconstructing the annular nozzle in. the shape of a horseshoe to achieve a shorter delay in blasting a molten droplet from the tip of a rod. Both methods were judged feasible for producing fibers of glasses requiring rapid freezing. The first method would be more amenable to volume fiber production. Studies of induction heating for fiber formation did not lead to its designation as a very efficient heating method. Problems. remain to be solved, in the design of a suitable susceptor for a higher heating rate, in protecting the susceptor from oxidation with an inert gas, in contamination of the melt from a refractory crucible, and in the protective radiation shielding of the induction concentrator coil. It is not considered practical to continue studies of this heating method. In the course of this program 151 refractory glass compositions were evaluated for fiber, forming characteristics. Of the various types of materials studied, the following showed promise in producing acceptable refractory fibers: sIlica- spinel (magnesium aluminate), silica- spinel-zirconia, silica-zirconia, silica-zinc spinel, aluminum phosphate glasses, and fluoride glasses. Compositions which did not produce acceptable fibers were high zirconia materials, barium spinels, and calcium aluminates. Improvements in the. testing apparatus for single fiber tensile strength increased the precision. of tests conducted on nine fibers. The highest mean tensile strength, a value of 295,000 pounds per square inch, was obtained with R-141 fibers. Treatment of R-74 fibers with anhydrous Linde A-1100 silane finish improved its mean fiber tensile strength by 25 percent. The lapse of time after fiber formation had no measurable effect on tensile strength. A static heating test conducted with various high melting fibers indicated that Fiberfrax and R-108 underwent no significant changes in bulk volume or resiliency on exposure to 2750 degrees Fahrenheit (1510 degrees Centigrade) in an oxidizing atmosphere. For fiber-resin composition fabrication, ten fiber materials were selected on the bases of high fiber yield, fusion temperature, and type of composition. Fiberfrax, a commercial ceramic fiber, was included for comparison. A new, more effective method of removing pellets from blown fibers was developed. The de-pelletized fibers were treated with a silane finish and felted into ten-inch diameter felts prior to resin impregnation. Composites containing 30 percent by weight of CTL 91-LD phenolic resin were molded under high pressure from the impregnated felts and post-cured to achieve optimum properties. Flexural strength, flexural modules of elasticity, and punch shear strength tests were conducted on the composite specimens. The highest average flexural strength obtained was 19,958 pounds per square inch with the R-74-fiber-resin composite. This compares very favorably with the military specification of 13,000 pounds per square inch flexural strength for randomly oriented fiber reinforced composites. The highest punch shear strength (11,509 pounds per square inch) was obtained with the R-89 fiber-resin composite. The effects of anhydrous fiber finishes on composite strength were not clearly indicated. Plasma arc tests at a heat flux of 550 British Thermal Units per square foot per second on eight composite materials indicated ablation rates generally equivalent to Fiberglas-Micarta No. 259-2. The composite reinforced with R-99 fibers had an average ablation rate of 0.008 inch per second and appears quite promising on the basis of these tests. Preliminary studies for processing fibers into yarn and fabric were conducted with R-99 fibers. The use of certain organic gums aided in 2 fabricating by hand several relatively strong yarns and a crude fabric swatch. This indicated the practicality of developing techniques for processing these fibers into yarn and fabric without significant damage to the fibers.

Gates, L. E.↗