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Understanding Variability in Mechanical Behavior of Adhesively Bonded Sandwich Joints due to Stochastic Material Damage

A mesoscale progressive damage analysis was applied to the analysis of recently tested adhesively bonded sandwich panels, in which ten nominally identical tension loaded panels failed in three different failure modes, with peakloads ranging from 13.0 –16.1 kips. A parametric finite element model for progressive damage analysis of an adhesively bonded joint (ABJ) considering matrix and fiber damage, and delamination cracks in unidirectional and fabric composite sections of the joint, as well as core crushing, and adhesive fracture was developed. The model was developed using Abaqus/Explicit and utilized continuum damage mechanics material models for intralaminar damage in the facesheet and doubler plies, cohesive elements for delamination and adhesive debonding, and discretized cells considering plasticity to model crushing of the aluminum honeycomb core. Analysis predictions obtained with a pristine model agreed well with the average experimental peak load, strain in the joint, and post-test damage states. Then, various methods to incorporate stochastic material variability into ABJ model were evaluated. These methods included simulation of pre-existing matrix damage, pre-existing adhesive porosity, and uniform modification of adhesive properties. These material and manufacturing defects changed the damage mode predictions in some cases. The analysis of stochastic strength due to the considered defects revealed unintuitive damage mode interaction in the ABJ, explaining some structure-property relationships observed experimentally.

Richard Larson↗

NASA NTRS1998

Fracture Mechanics Analysis of Stitched Stiffener-Skin Debonding

An analysis based on plate finite elements and the virtual crack closure technique has been implemented to study the effect of stitching on mode I and mode II strain energy release rates for debond configurations. The stitches were modeled as discrete nonlinear fastener elements with a compliance determined by experiment. The axial and shear behavior of the stitches was considered, however, the two compliances and failure loads were assumed to be independent. Both a double cantilever beam (mode I) and a mixed mode skin-stiffener debond configuration were studied. In the double cantilever beam configurations, G(sub I) began to decrease once the debond had grown beyond the first row of stitches and was reduced to zero for long debonds. In the mixed-mode skin-stiffener configurations, G(sub I) showed a similar behavior as in the double cantilever beam configurations, however, G(sub u), continued to increase with increasing debond length.

Glaessgen, E. H.↗

NASA NTRS2001

Analyses for Debonding of Stitched Composite Sandwich Structures Using Improved Constitutive Models

A fracture mechanics analysis based on strain energy release rates is used to study the effect of stitching in bonded sandwich beam configurations. Finite elements are used to model the configurations. The stitches were modeled as discrete nonlinear spring elements with a compliance determined by experiment. The constitutive models were developed using the results of flatwise tension tests from sandwich material rather than monolithic material. The analyses show that increasing stitch stiffness, stitch density and debond length decrease strain energy release rates for a fixed applied load.

Glaessgen, E. H.↗

NASA NTRS2013

Progressive Damage Modeling of Durable Bonded Joint Technology

The development of durable bonded joint technology for assembling composite structures for launch vehicles is being pursued for the U.S. Space Launch System. The present work is related to the development and application of progressive damage modeling techniques to bonded joint technology applicable to a wide range of sandwich structures for a Heavy Lift Launch Vehicle. The joint designs studied in this work include a conventional composite splice joint and a NASA-patented Durable Redundant Joint. Both designs involve a honeycomb sandwich with carbon/epoxy facesheets joined with adhesively bonded doublers. Progressive damage modeling allows for the prediction of the initiation and evolution of damage. For structures that include multiple materials, the number of potential failure mechanisms that must be considered increases the complexity of the analyses. Potential failure mechanisms include fiber fracture, matrix cracking, delamination, core crushing, adhesive failure, and their interactions. The joints were modeled using Abaqus parametric finite element models, in which damage was modeled with user-written subroutines. Each ply was meshed discretely, and layers of cohesive elements were used to account for delaminations and to model the adhesive layers. Good correlation with experimental results was achieved both in terms of load-displacement history and predicted failure mechanisms.

Leone, Frank A.↗

NASA NTRS1982

Materials characterization and fracture mechanics of a space grade dielectric silicone insulation

The present investigation is concerned with the DC 93-500 high voltage silicone insulation material employed to pot the gun and the collector end of a traveling wave tube (TWT) used on the Landsat D Satellite. The fracture mechanics behavior of the silicone resin was evaluated by measuring the slow crack velocity as a function of the opening mode of the stress intensity factor at +25 and -10 C, taking into account various uniaxial discrete strain values. It was found that the silicone resins slow crack growth is faster than that for a high voltage insulation polyurethane material at the same stress intensity factor value and room temperature.

Abdel-Latif, A. I.↗

NASA NTRS1990

The development of physically based micro-mechanics - Based on the characteristic tip field of dislocation pileup

Based on the analytical solution by Eshelby et al. (1951) and the numerical calculations by Chou and Li (1969) and Armstrong et al. (1962), it is shown that the force, F, on the locked leading dislocation of a discrete dislocation pileup is capable of characterizing uniquely the stress, strain, and displacement field at the tip of the pileup, including the positions of the discrete mobile dislocations next to the leading dislocation. Conversely, the positions of the mobile dislocations can be used to measure F. The F thus measured can be used to study micro-plastic deformation and micro-fractures at grain boundaries or any other dislocation barriers.

Gao, Q.↗

NASA NTRS2012

Progressive Damage Analysis of Bonded Composite Joints

The present work is related to the development and application of progressive damage modeling techniques to bonded joint technology. The joint designs studied in this work include a conventional composite splice joint and a NASA-patented durable redundant joint. Both designs involve honeycomb sandwich structures with carbon/epoxy facesheets joined using adhesively bonded doublers.Progressive damage modeling allows for the prediction of the initiation and evolution of damage within a structure. For structures that include multiple material systems, such as the joint designs under consideration, the number of potential failure mechanisms that must be accounted for drastically increases the complexity of the analyses. Potential failure mechanisms include fiber fracture, intraply matrix cracking, delamination, core crushing, adhesive failure, and their interactions. The bonded joints were modeled using highly parametric, explicitly solved finite element models, with damage modeling implemented via custom user-written subroutines. Each ply was discretely meshed using three-dimensional solid elements. Layers of cohesive elements were included between each ply to account for the possibility of delaminations and were used to model the adhesive layers forming the joint. Good correlation with experimental results was achieved both in terms of load-displacement history and the predicted failure mechanism(s).

Leone, Frank A., Jr.↗

NASA NTRS2024

Physics of the Seasonal Sea Ice Zone

The seasonal sea ice zone encompasses the region between the winter maximum and summer minimum sea ice extent. In both the Arctic and Antarctic, the majority of the ice cover can now be classified as seasonal. Here, we review the sea ice physics that governs the evolution of seasonal sea ice in the Arctic and Antarctic, spanning sea ice growth, melt, and dynamics and including interactions with ocean surface waves as well as other coupled processes. The advent of coupled wave–ice modeling and discrete-element modeling, together with improved and expanded satellite observations and field campaigns, has yielded advances in process understanding. Many topics remain in need of further investigation, including rheologies appropriate for seasonal sea ice, wave-induced sea ice fracture, welding for sea ice freeze-up, and the distribution of snow on seasonal sea ice. Future research should aim to redress biases (such as disparities in focus between the Arctic and Antarctic and between summer and winter processes) and connect observations to modeling across spatial scales.

sea ice↗

NASA NTRS2015

Face Sheet/Core Disbond Growth in Honeycomb Sandwich Panels Subjected to Ground-Air-Ground Pressurization and In-Plane Loading

Typical damage modes in light honeycomb sandwich structures include face sheet/core disbonding and core fracture, both of which can pose a threat to the structural integrity of a component. These damage modes are of particular interest to aviation certification authorities since several in-service occurrences, such as rudder structural failure and other control surface malfunctions, have been attributed to face sheet/core disbonding. Extensive studies have shown that face sheet/core disbonding and core fracture can lead to damage propagation caused by internal pressure changes in the core. The increasing use of composite sandwich construction in aircraft applications makes it vitally important to understand the effect of ground-air-ground (GAG) cycles and conditions such as maneuver and gust loads on face sheet/core disbonding. The objective of the present study was to use a fracture mechanics based approach developed earlier to evaluate the loading at the disbond front caused by ground-air-ground pressurization and in-plane loading. A honeycomb sandwich panel containing a circular disbond at one face sheet/core interface was modeled with three-dimensional (3D) solid finite elements. The disbond was modeled as a discrete discontinuity and the strain energy release rate along the disbond front was computed using the Virtual Crack Closure Technique (VCCT). Special attention was paid to the pressure-deformation coupling which can decrease the pressure load within the disbonded sandwich section significantly when the structure is highly deformed. The commercial finite element analysis software, Abaqus/Standard, was used for the analyses. The recursive pressure-deformation coupling problem was solved by representing the entrapped air in the honeycomb cells as filled cavities in Abaqus/Standard. The results show that disbond size, face sheet thickness and core thickness are important parameters that determine crack tip loading at the disbond front. Further, the pressure-deformation coupling was found to have an important load decreasing effect [6]. In this paper, a detailed problem description is provided first. Second, the analysis methodology is presented. The fracture mechanics approach used is described and the specifics of the finite element model, including the fluid-filled cavities, are introduced. Third, the initial model verification and validation are discussed. Fourth, the findings from a closely related earlier study [6] are summarized. These findings provided the basis for the current investigation. Fifth, an aircraft ascent scenario from 0 to 12192 m (0 to 40000 ft) is considered and the resulting crack tip loading at the disbond front is determined. In-plane loading to simulate maneuvers and gust conditions are also considered. Sixth, the results are shown for a curved panel, which was used to simulate potential fuselage applications. Finally, a brief summary of observations is presented and recommendations for improvement are provided.

Chen, Zhi M.↗

NASA NTRS1984

Numerical Investigation of the Micromechanics of Composite Fracture

A generalized program for the two-dimensional analysis of static crack growth problems was developed and is being tested. In addition to a detailed examination and development of fracture criteria needed to track cracks in composites at the micromechanical level, the program employs fully automatic finite element mesh generation. This is an entirely new approach in program structure that is being taken to allow for the automatic tracking of discrete crack growth. The maximum strain energy density criterion (T-criterion) was found to be a good alternative to the minimum strain energy density criterion (S-criterion).

Source record↗

NASA NTRS1996

A Mixed Finite Volume Element Method for Flow Calculations in Porous Media

A key ingredient in the simulation of flow in porous media is the accurate determination of the velocities that drive the flow. The large scale irregularities of the geology, such as faults, fractures, and layers suggest the use of irregular grids in the simulation. Work has been done in applying the finite volume element (FVE) methodology as developed by McCormick in conjunction with mixed methods which were developed by Raviart and Thomas. The resulting mixed finite volume element discretization scheme has the potential to generate more accurate solutions than standard approaches. The focus of this paper is on a multilevel algorithm for solving the discrete mixed FVE equations. The algorithm uses a standard cell centered finite difference scheme as the 'coarse' level and the more accurate mixed FVE scheme as the 'fine' level. The algorithm appears to have potential as a fast solver for large size simulations of flow in porous media.

Jim E Jones↗

NASA NTRS1990

The method of lines in analyzing solids containing cracks

A semi-numerical method is reviewed for solving a set of coupled partial differential equations subject to mixed and possibly coupled boundary conditions. The line method of analysis is applied to the Navier-Cauchy equations of elastic and elastoplastic equilibrium to calculate the displacement distributions in various, simple geometry bodies containing cracks. The application of this method to the appropriate field equations leads to coupled sets of simultaneous ordinary differential equations whose solutions are obtained along sets of lines in a discretized region. When decoupling of the equations and their boundary conditions is not possible, the use of a successive approximation procedure permits the analytical solution of the resulting ordinary differential equations. The use of this method is illustrated by reviewing and presenting selected solutions of mixed boundary value problems in three dimensional fracture mechanics. These solutions are of great importance in fracture toughness testing, where accurate stress and displacement distributions are required for the calculation of certain fracture parameters. Computations obtained for typical flawed specimens include that for elastic as well as elastoplastic response. Problems in both Cartesian and cylindrical coordinate systems are included. Results are summarized for a finite geometry rectangular bar with a central through-the-thickness or rectangular surface crack under remote uniaxial tension. In addition, stress and displacement distributions are reviewed for finite circular bars with embedded penny-shaped cracks, and rods with external annular or ring cracks under opening mode tension. The results obtained show that the method of lines presents a systematic approach to the solution of some three-dimensional mechanics problems with arbitrary boundary conditions. The advantage of this method over other numerical solutions is that good results are obtained even from the use of a relatively coarse grid.

Gyekenyesi, John P.↗

NASA NTRS1990

Micromechanical model of crack growth in fiber reinforced ceramics

A model based on the micromechanical mechanism of crack growth resistance in fiber reinforced ceramics is presented. The formulation of the model is based on a small scale geometry of a macrocrack with a bridging zone, the process zone, which governs the resistance mechanism. The effect of high toughness of the fibers in retardation of the crack advance, and the significance of the fiber pullout mechanism on the crack growth resistance, are reflected in this model. The model allows one to address issues such as influence of fiber spacing, fiber flexibility, and fiber matrix friction. Two approaches were used. One represents the fracture initiation and concentrated on the development of the first microcracks between fibers. An exact closed form solution was obtained for this case. The second case deals with the development of an array of microcracks between fibers forming the bridging zone. An implicit exact solution is formed for this case. In both cases, a discrete fiber distribution is incorporated into the solution.

Rubinstein, Asher A.↗

NASA NTRS1990

Micromechanical model of crack growth in fiber reinforced brittle materials

Rubinstein, Asher A.↗

NASA NTRS2011

Modeling and Characterization of Damage Processes in Metallic Materials

This paper describes a broad effort that is aimed at understanding the fundamental mechanisms of crack growth and using that understanding as a basis for designing materials and enabling predictions of fracture in materials and structures that have small characteristic dimensions. This area of research, herein referred to as Damage Science, emphasizes the length scale regimes of the nanoscale and the microscale for which analysis and characterization tools are being developed to predict the formation, propagation, and interaction of fundamental damage mechanisms. Examination of nanoscale processes requires atomistic and discrete dislocation plasticity simulations, while microscale processes can be examined using strain gradient plasticity, crystal plasticity and microstructure modeling methods. Concurrent and sequential multiscale modeling methods are being developed to analytically bridge between these length scales. Experimental methods for characterization and quantification of near-crack tip damage are also being developed. This paper focuses on several new methodologies in these areas and their application to understanding damage processes in polycrystalline metals. On-going and potential applications are also discussed.

Glaessgen, E. H.↗

NASA NTRS2019

Benchmarking Mixed Mode Failure in Progressive Damage and Failure Analysis Methods

The verification and validation of progressive-damage-analysis finite element methods are difficult but critical tasks to undertake during their development. Verification exercises assess whether a predictive analysis tool produces results that are consistent with the fundamental concepts and assumptions of the tool under evaluation. Ideally, closed-form analytical solutions can be derived for which method verification results can be compared. Problems selected for computational tool verification are often simple and isolate individual features of the tool. In the case of progressive damage finite element methods, verifications should be performed to evaluate the ability of the model to predict the initiation of damage and its growth through the finite element mesh under a variety of conditions. Mabson et al. proposed a test case of a unidirectional, fiber-reinforced plate with a center crack subjected to tensile loads to evaluate matrix crack propagation predictions. The problem was modeled using the Abaqus Hashin continuum damage mechanics (CDM) model for fiber-reinforced composites. Different combinations of matrix strengths and element sizes were used in the simulations, and the results were compared to a closed-form solution based on linear elastic fracture mechanics (LEFM). It was determined that the Abaqus CDM model could predict the LEFM solution of Mode I cracks only when the finite element mesh density met specific requirements based on the material properties. This paper presents closed-form LEFM solutions for a center notch mixed mode (CNMM) verification problem. Parametric finite element analyses were developed using progressive damage analysis methods of both the Discrete Damage Mechanics (DDM) and CDM classes. The progressive damage analysis methods applied in the analyses of the CNMM problem include CompDam and the Floating Node Method. Analyses were conducted with various mode mixities and element sizes to verify that the damage models were working as intended and to identify any limits of applicability.

Leone, Frank↗

NASA NTRS2004

Discrete Spring Model for Predicting Delamination Growth in Z-Fiber Reinforced DCB Specimens

Beam theory analysis was applied to predict delamination growth in DCB specimens reinforced in the thickness direction with pultruded pins, known as Z-fibers. The specimen arms were modeled as cantilever beams supported by discrete springs, which were included to represent the pins. A bi-linear, irreversible damage law was used to represent Z-fiber damage, the parameters of which were obtained from previous experiments. Closed-form solutions were developed for specimen compliance and displacements corresponding to Z-fiber row locations. A solution strategy was formulated to predict delamination growth, in which the parent laminate mode I fracture toughness was used as the criterion for delamination growth. The solution procedure was coded into FORTRAN 90, giving a dedicated software tool for performing the delamination prediction. Comparison of analysis results with previous analysis and experiment showed good agreement, yielding an initial verification for the analytical procedure.

Ratcliffe, James G.↗

NASA NTRS2003

Jupiter System Data Analysis Program: Mechanisms, Manifestation, and Implications of Cryomagmatism on Europa

The objectives of the work completed under NASA Grant NAG5-8898 were (i) to document and characterize the low-albedo diffuse surfaces associated with triple bands and lenticulae, (ii) to determine their mechanisms of formation, and (iii) to assess the implications of these features for the resurfacing (in space and time) of the Europa and the nature of the Europan interior. The approach involved a combination of processing and analysis of Solid State Imaging data returned by the Galileo spacecraft during the primary and extended mission phases, together with numerical modeling of the physical processes interpreted to the observed features. We have modeled the formation of Europan triple explosive venting of cryoclastic material from bands and lenticulae halos by two processes: (i) a liquid layer in the Europan interior, and (ii) lag deposit formation by the thermal influence of subsurface cryomagmatic intrusions. We favor the latter hypothesis for explaining these features, and further suggest that a liquid water or brine intrusion is required to provide sufficient lateral heating of surface ice to explain the 25 km size of the largest features. (Solid ice diapirs, even under the most favorable conditions, become thermally exhausted before they heat significant lateral distances). We argue that water circulating in open fractures, or repeated cryomagmatic 'diking' events would provide sufficient thermal input to produce the observed features. Thus our work argues for the existence of a liquid beneath Europa's surface. Our results might most easily be explained by the presence of a continuous liquid layer (the putative Europan ocean); this would concur with the findings of the Galileo magnetometer team. However, we cannot rule out the possibility that discrete liquid pockets provide injections of fluid closer to the surface.

Fagents, Sarah A.↗