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All sources NASA NTRS DOE OSTI

DOE OSTI2023

Effect of recycled fibers and shredded intermediates variation on the mechanical properties and energy absorption of fiber‐reinforced composite panels

Abstract The global composite industry generates large quantities of waste which mostly ends up in landfills due to a lack of established end‐use applications for multiple waste streams. The scrap from end‐of‐life (EoL) includes manufacturing waste such as dry chopped fiber tows, loose fibers, shredded fibers from fabric textile operations, cured/semi‐cured prepregs, and fully cured composite structure waste from aircraft, automobiles, wind blades, boats, and pressure vessels. In this work, different composite waste streams were reduced to shredded intermediates, followed by simple blending, and subjected to wet compression molding to produce composite panels. The panels/plaques were tested for mechanical properties (flexure and impact), fiber‐matrix wet‐out, and property bounds. It was found that wet‐compression molding was a viable and scale‐able approach to produce recycled panels from EoL composites shredded scrap. Furthermore, full‐scale size panels for use in truck bodies and intermodal shipping container flooring were manufactured and their impact resistance was tested using a drop weight impact test. They were tested both for high‐ and low‐velocity load. In the case of high‐velocity load, the average impact load was 14,673 N; the average absorbed energy was 101.6 J; the average elastic energy was 11.7 J and the impact resistance was 1065 J/m. In the case of the low‐velocity drop weight impact test, it was found that the average impact load was 7877.358 N; the average absorbed energy was 9.718 J; the average elastic energy was 9.14 J, and the impact resistance was 184.1 J/m. The shredded composite was shown to be a candidate material for the manufacture of truck bodies and intermodal containers’ flooring panels. Highlights By using shredded intermediates from different composite waste streams, it is possible to manufacture composite panels. Wet–compression process is an appropriate technique for manufacturing recycled fiber composite panels. Regardless of the source of scrap, the mechanical properties of the produced composite panels were improved. The recycling process technology can be transformed to commercial scale to produce full‐size transportation flooring panels. A product pathway is established in consideration of lower cost and improved recyclability.

Vaidya, Uday↗

NASA NTRS1991

An examination of the damage tolerance enhancement of carbon/epoxy using an outer lamina of spectra (R)

Low velocity instrumented impact testing was utilized to examine the effects of an outer lamina of ultra-high molecular weight polyethylene (Spectra) on the damage tolerance of carbon epoxy composites. Four types of 16-ply quasi-isotropic panels (0, +45, 90, -45) were tested. Some panels contained no Spectra, while others had a lamina of Spectra bonded to the top (impacted side), bottom, or both sides of the composite plates. The specimens were impacted with energies up to 8.5 J. Force time plots and maximum force versus impact energy graphs were generated for comparison purposes. Specimens were also subjected to cross-sectional analysis and compression after impact tests. The results show that while the Spectra improved the maximum load that the panels could withstand before fiber breakage, the Spectra seemingly reduced the residual strength of the composites.

Lance, D. G.↗

DOE OSTI2020

Comparison of woven and stitched out-of-autoclave E-glass/epoxy composites subjected to quasi-static and cyclic tensile loads

Tensile quasi-static and fatigue behaviors of out-of-autoclave, quasi-isotropic, E-glass/epoxy composites with woven and stitched fiber architectures are compared. Some specimens were cyclically loaded to failure, while others were tested for residual modulus and ultimate strength. Both laminates survived 10 7 cycles at a maximum stress of 94.8 MPa but failed prior to 10 7 cycles at a maximum stress greater than or equal to 124.1 MPa. For the stress-lifetime diagram and residual strength, the woven laminate had superior properties below 10 4 cycles and the stitched laminate had superior properties above 10 5 cycles. While intralaminar crack density was higher in the stitched laminate, the woven laminate demonstrated a higher percentage of delaminated area.

Materials Science↗

NASA NTRS1981

Acoustic emission monitoring of polymer composite materials

The techniques of acoustic emission monitoring of polymer composite materials is described. It is highly sensitive, quasi-nondestructive testing method that indicates the origin and behavior of flaws in such materials when submitted to different load exposures. With the use of sophisticated signal analysis methods it is possible the distinguish between different types of failure mechanisms, such as fiber fracture delamination or fiber pull-out. Imperfections can be detected while monitoring complex composite structures by acoustic emission measurements.

Bardenheier, R.↗

NASA NTRS1984

Composite interlaminar fracture - Effect of matrix fracture energy

A major result of the use of the double cantilever beam test to provide a measure of the interlaminar fracture energy in composites subjected to simple Mode I-type loading is the observation that increasing the toughness of the matrix resin by as much as a factor of 20 produced a major (approximately four-fold) increase in interlaminar fracture energy. The data presently analyzed show that, with brittle polymers, resin toughness is fully transferred to the composite, while in the case of tougher polymers the resin toughness is only partially transferred due to the fibers' restriction of the crack tip deformation zone in the polymer, together with their changing of local stress field details. Factors which tend to increase interlaminar toughness are fiber nesting and bridging, as well as fiber breakage and pull-out during crack growth.

Hunston, D. L.↗

NASA NTRS1992

An evaluation of mixed-mode delamination failure criteria

Many different failure criteria have been suggested for mixed mode delamination toughness, but few sets of mixed mode data exist that are consistent over the full mode I opening to mode II shear load range. The mixed mode bending (MMB) test was used to measure the delamination toughness of a brittle epoxy composite, a state of the art toughened epoxy composite, and a tough thermoplastic composite over the full mixed mode range. To gain insight into the different failure responses of the different materials, the delamination fracture surfaces were also examined. An evaluation of several failure criteria which have been reported in the literature was performed, and the range of responses modeled by each criterion was analyzed. A new bilinear failure criterion was analyzed. A new bilinear failure criterion was developed based on a change in the failure mechanism observed from the delamination surfaces. The different criteria were compared to the failure criterion. The failure response of the tough thermoplastic composite could be modeled well with the bilinear criterion but could also be modeled with the more simple linear failure criterion. Since the materials differed in their mixed mode failure response, mixed mode delamination testing will be needed to characterize a composite material. A critical evaluation is provided of the mixed mode failure criteria and should provide general guidance for selecting an appropriate criterion for other materials.

Reeder, J. R.↗

NASA NTRS1993

Humidity effects on soluble core mechanical and thermal properties (polyvinyl alcohol/microballoon composite) type CG extendospheres, volume 2

This document constitutes the final report for the study of humidity effects and loading rate on soluble core (PVA/MB composite material) mechanical and thermal properties under Contract No. 100345. This report describes test results procedures employed, and any unusual occurrences or specific observations associated with this test program. The primary objective of this work was to determine if cured soluble core filler material regains its tensile and compressive strength after exposure to high humidity conditions and following a drying cycle. Secondary objectives include measurements of tensile and compressive modulus, and Poisson's ratio, and coefficient of thermal expansion (CTE) for various moisture exposure states. A third objective was to compare the mechanical and thermal properties of the composite using 'SG' and 'CG' type extendospheres. The proposed facility for the manufacture of soluble cores at the Yellow Creek site incorporates no capability for the control of humidity. Recent physical property tests performed with the soluble core filler material showed that prolonged exposure to high humidity significantly degradates in strength. The purpose of these tests is to determine if the product, process or facility designs require modification to avoid imparting a high risk condition to the ASRM.

Source record↗

NASA NTRS2000

Development and Testing of Cooled CMCs for High Thermal Flux Applications

Ceramic Matrix Composites (CMCS) offer the potential for significant weight savings and improved performance for a range of propulsion components utilizing refractory materials. This paper describes the fabrication and testing of functionally graded CMCs produced via a low cost process that represents an order of magnitude cost savings over conventionally fabricated CMCS. Test cylinders were fabricated, characterized and evaluated during exposure to high thermal fluxes of up to 10MW/meters squared at the Laser Hardened Materials Evaluation Laboratory (LHMEL). The bulk density of the CMC tubes was approximately 2.2 grams per cubic centimeters. The performance of cryogenically cooled CMCs was compared with uncooled CMCs against similar thermal loads, and fundamental property data collected for this relatively new breed of CMC. Finally, test thrust cells were fabricated from the functionally graded composite and tested using liquid H2 and O2 propellants at NASA Glen.

Patterson , Mark↗

NASA NTRS1991

Characterization and modeling of tensile behavior of ceramic woven fabric composites

This paper examines the tensile behavior of SiC/SiC fabric composites. In the characterization effort, the stress-strain relation and damage evolution are studied with a series of loading and unloading tensile test experiments. The stress-strain relation is linear in response to the initial loading and becomes nonlinear when loading exceeds the proportional limit. Transverse cracking has been observed to be a dominant damage mode governing the nonlinear deformation. The damage is initiated at the inter-tow pores where fiber yarns cross over each other. In the modeling work, the analysis is based upon a fiber bundle model, in which fiber undulation in the warp and fill directions and gaps among fiber yarns have been taken into account. Two limiting cases of fabric stacking arrangements are studied. Closed form solutions are obtained for the composite stiffness and Poisson's ratio. Transverse cracking in the composite is discussed by applying a constant failure strain criterion.

Kuo, Wen-Shyong↗

DOE OSTI2023

Infusible Thermoplastic Composites for Wind Turbine Blade Manufacturing: Fatigue Life of Thermoplastic Laminates under Ambient and Low-Temperature Conditions

Traditionally, thermoset resins such as polyesters (PE) and epoxies are used as the polymer matrix for construction of wind turbine blades. However, concern about their end-of-life treatment garners interest to use thermoplastics for increased recyclability. However, the high viscosity of molten thermoplastics inhibits their use in manufacturing wind turbine blades with injection or compression molding. A recently developed, infusible, reactive thermoplastic resin overcomes this technological barrier. Toward verifying that this recyclable resin is suitable for use in wind turbine blades, a dataset of R?=?0.1 and R?=?10 fatigue data for glass fiber-reinforced acrylic composites is provided and equal fatigue life to industry standard epoxy and unsaturated PE resin systems is demonstrated. Specifically, R?=?0.1 fatigue data for acrylic composites at room temperature and -30?degrees C for verification of low-temperature performance are tabulated. To elucidate failure mechanisms, in situ mechanical testing with X-ray computed tomography demonstrates that damage accumulation occurs by crack propagation along the fiber-matrix interface under cyclic loading. Infrared (IR) thermography predicts failure points in composites specimens with porosity defects introduced from nonideal manufacturing processes. Furthermore, these manufacturing defects are shown to compromise the fatigue life of the acrylic laminates by an order of magnitude.

effect of defects↗

NASA NTRS2000

BMI Sandwich Wing Box Analysis and Test

A composite sandwich single bay wing box test article was developed by Northrop Grumman and tested recently at NASA Langley Research Center. The objectives for the wing box development effort were to provide a demonstration article for manufacturing scale up of structural concepts related to a high speed transport wing, and to validate the structural performance of the design. The box concept consisted of highly loaded composite sandwich wing skins, with moderately loaded composite sandwich spars. The dimensions of the box were chosen to represent a single bay of the main wing box, with a spar spacing of 30 inches, height of 20 inches constant depth, and length of 64 inches. The bismaleimide facesheet laminates and titanium honeycomb core chosen for this task are high temperature materials able to sustain a 300F service temperature. The completed test article is shown in Figure 1. The tests at NASA Langley demonstrated the structures ability to sustain axial tension and compression loads in excess of 20,000 lb/in, and to maintain integrity in the thermal environment. Test procedures, analysis failure predictions, and test results are presented.

Palm, Tod↗

NASA NTRS1981

Determination of load sequence effects on the degradation and failure of composite materials

A theoretical model was established to predict the fatigue behavior of composite materials, with emphasis placed on predictions of the degradation of residual strength and residual stiffness during fatigue cycling. The model parameters were evaluated from three test series including static strength fatigue life and residual strength tests. The tests were applied to two graphite/epoxy laminates. Load sequence effects were emphasized for both laminates and the predicted results agreed quite well with subsequent verification tests. Dynamic as well as static stiffness reduction data were collected by use of a PDP11-03 computer, which performed quite satisfactorily and permitted the recording of a substantial amount of dynamic stiffness reduction data.

Yang, J. N.↗

NASA NTRS1985

Interaction of mixed mode loading on cyclic debonding in adhesively bonded composite joints

A combined experimental and analytical investigation of an adhesively-bonded composite joint was conducted to characterize the fracture mode dependence of cyclic debonding. The system studied consisted of graphite/epoxy adherends bonded with EC 3445 adhesive. Several types of specimens are tested which provide the cyclic debond growth rate measurements under various load conditions: mode 1, mixed mode 1 to 2, and mostly mode 2. This study shows that the total strain-energy-release rate is the governing factor for cyclic debonding.

Mall, S.↗

NASA NTRS1985

Interaction of mixed mode loading on cyclic debonding in adhesively bonded composite joints

Mall, S.↗

NASA NTRS2018

Wide-field Infrared Survey Telescope (WFIRST): Composite Structure Verification for Operational Temperatures

The Wide-Field Infrared Survey Telescope (WFIRST) mission is the next large astrophysics observatory for NASA after the James Webb Space Telescope and is the top priority mission from the 2010 National Academy of Sciences' decadal survey. The WFIRST Optical Telescope Assembly (OTA) includes inherited composite support structures that were originally designed and tested for room temperature operation; however, the WFIRST mission will require operation at colder temperatures to achieve sufficient sensitivity for the infrared wavelengths. We will present the results and conclusions of testing completed at the coupon and engineering model level to verify that the inherited composite structures will maintain mechanical integrity and performance over the required temperature range. The testing included: (1) characterization testing of constituent material coupons, (2) thermal cycling and static load testing of a representative aft metering structure (AMS) and forward metering structure (FMS), and (3) thermal cycling and dynamic testing of a representative secondary mirror assembly (SMA).

metering↗

NASA NTRS1991

Sliding wear of self-mated Al2O3-SiC whisker reinforced composites at 23-1200 C

Microstructural changes occurring during sliding wear of self-mated Al2O3-SiC whisker reinforced composites were studied using optical, scanning electron microscopy, and transmission electron microscopy. Pin-on-disk specimens were slid in air at 2.7 m/sec sliding velocity under a 26.5 N load for 1 hr. Wear tests were conducted at 23, 600, 800, and 1200 C. Mild wear with a wear factor of 2.4 times 10(exp -7) to 1.5 times 10(exp -6) cu mm/Nm was experienced at all test temperatures. The composite shows evidence of wear by fatigue mechanisms at 800 C and below. Tribochemical reaction (SiC oxidation and reaction of SiO2 and Al2O3) leads to intergranular failure at 1200 C. Distinct microstructural differences existing at each test temperature are reported.

Farmer, Serene C.↗

NASA NTRS1973

Rubber compositions for hydrazine service

Forty-three compounds were formulated and tested for physical properties and hydrazine compatibility. Variables introduced include silicon dioxide filler loading level and particle size. Both butyl and ethylene-propylene rubbers were employed as well as various vulcanization systems. The data showed that compounds containing butyl and butyl blended with ethylene propylene could not be distinguished from ethylene propylene alone as far as chemical properties were concerned. A trend noted was that a filler level with higher silicon dioxide loading exhibited better hydrazine compatibility. Particle size variation did not show any consistent trends. Any of the vulcanization systems employed appeared to be satisfactory. A refined technique for dissolving aluminum cores from EPT-10 bladders was also tested.

Repar, J.↗

NASA NTRS1996

Strain Gage Selection Criteria for Textile Composite Materials

This report will provide a review of efforts to establish a set of strain gage selection guidelines for textile reinforced composite materials. A variety of strain gages were evaluated in the study to determine the sensitivity of strain measurements to the size of the strain gage. The strain gages were chosen to provide a range of gage lengths and widths. The gage aspect ratio (the length-to-width ratio) was also varied. The gages were tested on a diverse collection of textile composite laminates. Test specimens featured eleven different textile architectures: four 2-D triaxial braids, six 3-D weaves, and one stitched uniweave architecture. All specimens were loaded in uniaxial tension. The materials' moduli were measured in both the longitudinal (parallel to the O deg. yarns) and the transverse (perpendicular to the O deg. yarns) directions. The results of these measurements were analyzed to establish performance levels for extensometers and strain gages on textile composite materials. Conclusions are expressed in a summary that discusses instrumentation practices and defines strain gage selection criteria.

Masters, John E.↗