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NASA NTRSDate not supplied

Experimental Observations of Damage States in Unnotched and Notched 3D Orthogonal Woven Coupons Loaded in Tension

This paper describes a series of unnotched and notched tensile tests on two 3D orthogonal woven architectures. Dog bone specimens were used for the unnotched tests, and open-hole specimens were used for the notched tests. For each architecture and test type, two specimens were loaded under monotonic displacement control to failure and two specimens were incrementally loaded to failure in five steps. X-ray computed tomography (CT) was used to characterize the woven architecture and defects on each specimen prior to testing. Digital image correlation (DIC) images were obtained from both sides of the specimen throughout the loading and unloading. Acoustic emission (AE) data were also continuously acquired throughout the loading. For the incremental tests, X-ray CT was used to document the damage progression after each load increment. The damage progression was analyzed based on the results from these three techniques. The results for both architectures and test specimens followed a pattern where matrix cracks formed at the surface perpendicular to the tensile load direction. New surface cracks formed continuously throughout the loading and cracks extended in depth and width. In general, fiber failure was not detected until specimen failure.

Wade C Jackson↗

NASA NTRSDate not supplied

Experimental Observations of Damage States in Unnotched and Notched 3D Orthogonal Woven Coupons Loaded in Tension

This paper describes a series of unnotched and notched tensile tests on two 3D orthogonal woven architectures loaded in the warp direction. Dogbone specimens were used for the unnotched tests, and open-hole specimens were used for the notched tests. For each architecture and test type, two specimens were loaded under monotonic displacement control to failure, and two specimens were incrementally loaded to failure in five steps. X-ray computed tomography (CT) was used to characterize the woven architecture and defects on each specimen prior to testing. Digital image correlation (DIC) images were obtained from both sides of the specimen throughout the loading and unloading. For the incremental tests, X-ray CT was used to document the damage progression after each load increment. The results for both architectures and test specimens followed a similar pattern where matrix cracks formed perpendicular to the load direction and were primarily located between the stacks of warp tows. Two-piece failure path always occurred perpendicular to the loading direction, along the through-thickness segments of the Z-tows. The combination of stress concentrations due to the specimen geometry, weave geometry, and cut tows created stress concentrations that appear to initiate failure.

Woven materials↗

NASA NTRS1994

Micromechanics of fatigue in woven and stitched composites

The goals of this research program were to: (1) determine how microstructural factors, especially the architecture of reinforcing fibers, control stiffness, strength, and fatigue life in 3D woven composites; (2) identify mechanisms of failure; (3) model composite stiffness; (4) model notched and unnotched strength; and (5) model fatigue life. We have examined a total of eleven different angle and orthogonal interlock woven composites. Extensive testing has revealed that these 3D woven composites possess an extraordinary combination of strength, damage tolerance, and notch insensitivity in compression and tension and in monotonic and cyclic loading. In many important regards, 3D woven composites far outstrip conventional 2D laminates or stitched laminates. Detailed microscopic analysis of damage has led to a comprehensive picture of the essential mechanisms of failure and how they are related to the reinforcement geometry. The critical characteristics of the weave architecture that promote favorable properties have been identified. Key parameters are tow size and the distributions in space and strength of geometrical flaws. The geometrical flaws should be regarded as controllable characteristics of the weave in design and manufacture. In addressing our goals, the simplest possible models of properties were always sought, in a blend of old and new modeling concepts. Nevertheless, certain properties, especially regarding damage tolerance, ultimate failure, and the detailed effects of weave architecture, require computationally intensive stochastic modeling. We have developed a new model, the 'binary model,' to carry out such tasks in the most efficient manner and with faithful representation of crucial mechanisms. This is the final report for contract NAS1-18840. It covers all work from April 1989 up to the conclusion of the program in January 1993.

Cox, B. N.↗

NASA NTRS2013

Thermal and Structural Performance of Woven Carbon Cloth For Adaptive Deployable Entry and Placement Technology

Arcjet testing and analysis of a three-dimensional (3D) woven carbon fabric has shown that it can be used as a thermal protection system and as a load bearing structural component for a low ballistic coefficient hypersonic decelerator called ADEPT (Adaptive Deployable Entry and Placement Technology). Results of arcjet tests proved that the 3D woven carbon fabric can withstand flight-like heating while under flight-like biaxial mechanical loads representative of those encountered during shallow entry flight path angles into the atmosphere of Venus. Importantly, the arcjet test results have been used to extend a preliminary material thermal response model based on previous testing of the same 3D woven carbon fabric under uni-axial mechanical loading.

Carbon fabric↗

NASA NTRSDate not supplied

Next Generation Thermal Protection System for Outer Planet Probes and Orbiter

Saturn Probe and Ice Giant Orbiter along with in-situ Probe Missions continue to be very high priority mis-sions. A result of the advocacy by OPAG and other Analysis Groups, the 3D Woven, Dual-Layer HEEET thermal protection system, mature at TRL 6, has closed the TPS gap for extreme environment missions. A mid density follow on to DL HEEET, developed to meet earth entry requirements, is a Single Layer vari-ant of the 3D woven TPS, which provides a mass effi-cient single layer 3D Mid-Density TPS (3MDCP) that has been baselined as the heatshield for MSR EEV. Continued development of 3MDCP will elevate it to TRL 6 by 2025. Conformal-PICA (C-PICA) devel-opment was pursued to establish a more efficient and robust alternate to PICA, and it is at TRL 4+. Our rationale for the next generation of TPS de-velopment is based on the on the missions needs of the next decade Outer Planet missions that are unique and more demanding than any other destinations. Taking advantage of the recent planned development of sev-eral materials, the next generation of TPS offers a much more mass efficient option for small, medium, and large class Outer Planet missions. Saturn Probes: While mission designers are gen-erally interested in shallow entry to maintain the g-load during entry around 50g, the heat-load for shallow entry can range between (100 kJ/cm2 – 300 kJ/cm2), two orders of magnitude higher than Venus or Sample Return missions. TPS must not only offer protection but must be mass efficient to perform reasonable sci-ence. TPS mass can quickly become 50% or more of the mass of the entire entry system. Recent analysis performed shows Saturn Probe missions could signifi-cantly benefit from the single layer HEEET (SL-HEEET/3MDCP). A DL-HEEET based heatshield mass could be ~ (40% -50%), SL-HEEET can provide additional (30% - 50%) mass savings. At the same time, C-PICA can provide (30% - 50%) mass savings on the backshell. The combined mass savings can be significant enough to carry an additional probe, if de-sired. Ice Giant Aerocapture Missions: Aerocapture mission architectures can provide significant ad-vantage over traditional propulsive insertion missions in multiple ways. 1) Reduced trip time ~ (4- 6) years (30% -40%), 2) Enables placing the orbiter, probe, and lander, all together and 3) Allows for greater science mass (probes and landers) due to mass efficiency. The delivery of a probe from orbit makes it easier and eliminates mission design constraints by HEEET for direct entry [4] of probes and allows for more targeted in-situ science once the Orbiter is able to collect data. In the past 20 years, progress made in GN&C for lift-guided entry missions (MSL, Orion EFT1, Mars 2020) and the expertise in blunt body aerodynamics at large scale (~ 5m) has led the EDL community to conclude that aerocapture is a “go do” engineering activity. An aerocapture mission that will deplete the excess energy of a fast arrival mission will require a mass efficient TPS that can handle extreme heat-load, ~ (100 kJ/cm2 – 500 kJ/cm2). Hence TPS, feasibility as well as mass efficiency requires assessment. Utilizing the recent developments, a comprehensive, bounding analysis was done to establish the potential for SOA (HEEET) system as well as emerging new TPS such as SL-HEEET and C-PICA. In this proposed poster, we will outline the process by which we establish bounding aerocapture trajecto-ries for hyperbolic excess velocities ranging from 27 km/s to 35 km/s, for low L/D (~ 0.4) configurations and determine conservative/bounding estimate of aer-othermal environment by using a combination of CFD simulations and stagnation point heating estimates [7]. This engineering approach allows us to assess the TPS need vs. TPS capability and determine the applicability of existing TPS. Once an applicable suite of TPS is determined, the TPS thickness and mass are comput-ed. We show that the TPS mass fraction can be as low as 5% to as high as 20%, depending on the use of ad-vanced TPS, while HEEET is sufficient but will require 50% of the entry mass.

E Venkatapathy↗

NASA NTRS2011

Comparative Study of 3-Dimensional Woven Joint Architectures for Composite Spacecraft Structures

The National Aeronautics and Space Administration (NASA) Exploration Systems Mission Directorate initiated an Advanced Composite Technology (ACT) Project through the Exploration Technology Development Program in order to support the polymer composite needs for future heavy lift launch architectures. As an example, the large composite structural applications on Ares V inspired the evaluation of advanced joining technologies, specifically 3D woven composite joints, which could be applied to traditionally manufactured barrel segments. Implementation of these 3D woven joint technologies may offer enhancements in damage tolerance without sacrificing weight. However, baseline mechanical performance data is needed to properly analyze the joint stresses and subsequently design/down-select a preform architecture. Six different configurations were designed and prepared for this study; each consisting of a different combination of warp/fill fiber volume ratio and preform interlocking method (z-fiber, fully interlocked, or hybrid). Tensile testing was performed for this study with the enhancement of a dual camera Digital Image Correlation (DIC) system which provides the capability to measure full-field strains and three dimensional displacements of objects under load. As expected, the ratio of warp/fill fiber has a direct influence on strength and modulus, with higher values measured in the direction of higher fiber volume bias. When comparing the z-fiber weave to a fully interlocked weave with comparable fiber bias, the z-fiber weave demonstrated the best performance in two different comparisons. We report the measured tensile strengths and moduli for test coupons from the 6 different weave configurations under study.

Jones, Justin S.↗

NASA NTRS2011

Comparative Study of 3-Dimensional Woven Joint Architectures for Composite Spacecraft Structures

The National Aeronautics and Space Administration (NASA) Exploration Systems Mission Directorate initiated an Advanced Composite Technology (ACT) Project through the Exploration Technology Development Program in order to support the polymer composite needs for future heavy lift launch architectures. As an example, the large composite structural applications on Ares V inspired the evaluation of advanced joining technologies, specifically 3D woven composite joints, which could be applied to segmented barrel structures needed for autoclave cured barrel segments due to autoclave size constraints. Implementation of these 3D woven joint technologies may offer enhancements in damage tolerance without sacrificing weight. However, baseline mechanical performance data is needed to properly analyze the joint stresses and subsequently design/down-select a preform architecture. Six different configurations were designed and prepared for this study; each consisting of a different combination of warp/fill fiber volume ratio and preform interlocking method (Z-fiber, fully interlocked, or hybrid). Tensile testing was performed for this study with the enhancement of a dual camera Digital Image Correlation (DIC) system which provides the capability to measure full-field strains and three dimensional displacements of objects under load. As expected, the ratio of warp/fill fiber has a direct influence on strength and modulus, with higher values measured in the direction of higher fiber volume bias. When comparing the Z-fiber weave to a fully interlocked weave with comparable fiber bias, the Z-fiber weave demonstrated the best performance in two different comparisons. We report the measured tensile strengths and moduli for test coupons from the 6 different weave configurations under study.

Jones, Justin S.↗

NASA NTRS2019

Overview of the Development and Testing of the Heatshield for Extreme Entry Environment Technology (HEEET) TPS

Over the last 5 years, the Heatshield for Extreme Entry Environment Technology (HEEET) project has been working to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. A key aspect of the project has been the development of the manufacturing and integration processes/procedures necessary to build a heat shield utilizing the HEEET 3D-woven material. This has culminated in the building of a 1-meter diameter Engineering Test Unit (ETU) representative of what would be used for a Saturn probe. The present talk provides an overview of recent testing of NASA's Heatshield for Extreme Entry Environment Technology (HEEET) 3D Woven TPS. Under the current program, the ETU has been subjected to Thermal and Mechanical loads typical of deep space mission to Saturn. Thermal testing of HEEET coupons has performance up to 4,500 watts per centimeter squared at 5 atmospheres stagnation pressure and successful shear performance up to 3000 pascals at 1,650 watts per centimeter squared at 2.6 atmospheres pressure.

HEEET↗

NASA NTRSDate not supplied

Rocket Lab Venus - Enabling Low-Cost Interplanetary Missions

Rocket Lab’s mission to Venus, launching in January 2025, aims to demonstrate that small launch vehicles, such as Electron, and high-energy small spacecraft, such as Photon, can enable a new paradigm of regular, low-cost interplanetary missions. The primary science mission involves a small ~20 kg direct entry probe that will sample the Venusian cloud layers with an autofluorescing nephelomoeter. The entry probe thermal protection system (TPS) is even more critical than usual due to the selected entry trajectory and the lack of suitable heritage TPS materials. NASA’s newly developed 3D Woven Carbon Phenolic, a derivative of the Heatshield for Extreme Entry Environment Technology (HEEET) material, is an enabling technology for this mission, and it will comprise the probe forebody heat shield. The work that led to the selection of 3D Woven Carbon Phenolic, the TPS cost-reduction approaches taken, and the future possibilities of such an approach to probe development are presented.

Lyle Campbell↗

NASA NTRS1993

Acousto-Ultrasonic analysis of failure in ceramic matrix composite tensile specimens

Three types of acousto-ultrasonic (AU) measurements, stress-wave factor (SWF), lowest antisymmetric plate mode group velocity (VS), and lowest symmetric plate mode group velocity (VL), were performed on specimens before and after tensile failure. Three different Nicalon fiber architectures with ceramic matrices were tested. These composites were categorized as 1D (unidirectional fiber orientation) SiC/CAS glass ceramic, and 2D and 3D woven SiC/SiC ceramic matrix materials. SWF was found to be degraded after tensile failure in all three material categories. VS was found to be degraded only in the 1D SiC/CAS. VL was difficult to determine on the irregular specimen surfaces but appeared unchanged on all failed specimens. 3D woven specimens with heat-treatment at high temperature exhibited degradation only in SWF.

Kautz, Harold E.↗

NASA NTRS1995

Failure models for textile composites

The goals of this investigation were to: (1) identify mechanisms of failure and determine how the architecture of reinforcing fibers in 3D woven composites controlled stiffness, strength, strain to failure, work of fracture, notch sensitivity, and fatigue life; and (2) to model composite stiffness, strength, and fatigue life. A total of 11 different angle and orthogonal interlock woven composites were examined. Composite properties depended on the weave architecture, the tow size, and the spatial distributions and strength of geometrical flaws. Simple models were developed for elastic properties, strength, and fatigue life. A more complicated stochastic model, called the 'Binary Model,' was developed for damage tolerance and ultimate failure. These 3D woven composites possessed an extraordinary combination of strength, damage tolerance, and notch insensitivity.

Cox, Brian↗

NASA NTRS2020

Challenges of Testing EB Coated CMC under SPLCF Conditions in Steam Environment at High Temperatures

Environmental barrier (EB) coated monolithic SiC (Hexoloy) and 3D woven SiC/SiC composite specimens were tested under sustained peak low cycle fatigue (SPLCF) conditions at 1204°C at 69 MPa (maximum stress) in steam environment up to 200hrs. Both types of specimens were coated with a multilayer EB coating (Mullite + rare earth disilicate (RED) bond coat and RED top coat) by slurry method. The coated Hexoloy specimen survived 200hrs testing of testing, but the coating showed through-the-thickness cracks and delamination. In contrast, the coated 3D woven SiC/SiC composite specimens failed between 48 and 160 hrs and showed extensive damage in the coating as well as within the CMC substrate.

R T Bhatt↗

NASA NTRSDate not supplied

Rocket Lab Venus - Enabling Low-Cost Interplanetary Missions

Rocket Lab’s mission to Venus [1], launching in January 2025, aims to demonstrate that small launch vehicles, such as Electron, and high-energy small spacecraft, such as Photon, can enable a new paradigm of regular, low-cost interplanetary missions. The Electron launch vehicle will deliver the Photon spacecraft carrying the entry probe into low earth orbit, at which point Photon will take over and put both itself and the attached probe on an Earth-Venus transfer trajectory, with assistance from a Lunar flyby. The primary science objective of the mission is to sample the Venusian cloud layers between atitudes of 45 and 60 km above the surface with an autofluorescing nephelometer. The ~1kg scientific instrument will be carried by a small ~17 kg direct entry probe which will separate from the Photon spacecraft approximately 30 minutes prior to atmospheric entry. The probe outer mould line is a scaled down version of the Deep Space 2 probes [2]. NASA’s newly developed 3D Woven Carbon Phenolic, a derivative of the Heatshield for Extreme Entry Environment Technology (HEEET) material [3], is an enabling technology for this mission, and it will comprise the probe forebody heat shield.The probe will communicate directly back to the Earth during its descent via a small on-board radio frequency (RF) antenna. The hyperbolic Venus encounter will see the probe enter the Venusia atmosphere at approximately 11 km/s with an entry flight path angle (EFPA) of about 10°. This relatively low entry angle was selected to increase the duration of the descent phase, reduce the peak deceleration, and reduce the sensitivity of the nominal entry environments to navigational errors. For reference, the Pioneer Venus probes entered at EFPAs varying from about 25° to 70°, resulting in peak decelerations between around 220 and 450 g’s and peak stagnation point heat fluxes ranging from about 40 to 75 MW/m2 [4]. In comparison, the Rocket Lab Venus probe will experience a lower preak deceleration of around 60 g’s and a lower peak stagnation point heat flux of about 15 MW/m2, at the cost of a greater total heat load and correspondingly higher thermal protection system (TPS) mass fraction. This paper recounts the development history of the TPS for the Rocket Lab Venus probe, with a focus on the unique requirements of the mission. In particular, the effect on the TPS design of the mission’s tight budget, short development timeline, slim mass and RF link margins, and mild but long duration entry heating. Rocket Lab’s initial investigations into a ‘hybrid’ TPS [5] based on a scaled version of the Pioneer Venus full-density carbon phenolic forebody shield, and the abandonment of this approach in favour of NASA’s 3D Woven Carbon Phenolic is presented. Additionally, the leveraging of previous testing under the HEEET project at higher conditions and the associated TPS margining strategy that was adopted to avoid the need for extensive mission-specific arc jet testing is discussed. Finally, this paper concludes with a brief consideration of the feasibility of a future low-cost aerocapture technology demonstrator mission based on the 2025 Rocket Lab Venus mission and entry probe.

Lyle Campbell↗

NASA NTRS2015

Smart Book Charts

Smart book charts for TPSM: Heatshield for Extreme Entry Environment Technology (HEEET), Conformal Ablative TPS (CA-TPS), 3D Woven Multifunctional Ablative TPS (3D MAT), and Adaptable, Deployable, Entry and Placement Technology (ADEPT).

Conformal Ablative↗

NASA NTRSDate not supplied

Experimental Observations of Damage States in Unnotched and Notched 3D Orthogonal Woven Coupons Loaded in Tension

Explore the source record for details and available documents.

Wade Jackson↗

NASA NTRSDate not supplied

Thermomechanical Modeling of Woven Materials With Particle-Based, Explicit-Fiber Simulations

Fiber-based materials are extensively used to protect spacecraft during entry. Insulative fibers, often in a fiber network or woven, provide rigidity, strength, and control of material anisotropy and density. Woven thermal protection materials, such as ADEPT (Adaptable, Deployable Entry and Placement Technology), 3D-MAT (3-Dimensional Multifunctional Ablative Thermal Protection), and 3MDCP (3D Woven Mid-Density Carbon Phenolic), enable missions with stronger and denser materials for entry profiles with high shear and heat flux. Vulnerabilities to woven thermal protection materials include manufacturing-induced material property variation, and impact from micrometeoroids. Simulating woven materials under these conditions require models that can resolve hierarchal structures, thermomechanical behavior, and failure. To address this, we simulate weave thermal conduction and mechanical deformation. We simulate the full weave with a coarse-grained yarn model is presented. The model combines a validated, high-resolution single 3MDCP yarn model and phenolic resin model. Instead of modeling every fiber, each yarn ply with order 10, instead of order 1000, fibers. The discrete element bonded particle model (DEM-BPM) of fibers captures the thermal and mechanical behavior within and between fibers. We study the proportion of heat transfer and stress via the contact network, fiber bonds, and overall weave geometry.

bonded particle↗

NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials

Carbon and phenolic fibers are commonly used in ablative thermal protection materials, such as 3-dimensional Mid-Density Carbon Phenolic (3MDCP), a 3D-woven composite comprised of mixed-fiber yarn bundles. Predicting the micro-mechanical response and fracture of twisted yarns composed of brittle and ductile fibers requires a modeling approach that captures per-fiber yielding, fiber fracture, and inter-fiber friction and contact. This work presents an extended bonded particle model (BPM) for discrete element method (DEM) simulation of fiber and yarn mechanics, implemented in LAMMPS. The model builds on the incremental bond formulation of Guo et al. and introduces a piecewise elasto-plastic constitutive law for axial extension, enabling representation of fibers that yield before failure. 3MDCP yarns were constructed using measured fiber radius distributions and helical twist geometry. Tensile simulations of single-ply 3MDCP yarns show good agreement with vender stress–strain results. Fiber breakage models also show details on yarn breakage propagration, centered radially in the yarn. Yarn breakage of multi-ply 3MDCP also matched experimental observations in per-ply breakage; however, predicted yarn breakage strength were found higher than experimental observations.

Discrete Element Method↗

NASA NTRSDate not supplied

Simulations of Yarn Micro-Mechanics of Woven Heat Shield Materials (3MDCP)

Woven↗