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NASA NTRS2021

Latent Cure Epoxy Resins for Reliable Joints in Secondary-Bonded Composite Structures

In high-performance polymer matrix composite assemblies, adhesive bonding is generally superior to mechanical fastening in structural performance and manufacturing efficiency. However, adhesive bonds are susceptible to minute levels of contamination accumulated during assembly that can lead to unpredictable, weak bonds. Current methods of measuring bond strength are all destructive mechanical tests. To overcome these challenges, redundant load paths (e.g., mechanical fasteners) are often implemented in secondary-bonded, primary-structures, which can greatly reduce structural performance. This study investigated reformulated aerospace epoxy matrix resins with stoichiometric offset to inhibit cure of the matrix resin prior to assembly. Inhibited resins can reflow and mix across the joint interface, which eliminates the material discontinuity and forms a homogenous joint with reliable fracture properties. The goal of this study was to develop and demonstrate secondary composite assemblies that are mechanically and microscopically indistinguishable from a co-cured composite joint. This article describes the development of latent epoxy resins, the fabrication of test articles, and the mechanical properties measured from experimental joints compared with conventional, co-cured laminates. Methods of in-line quality control using and infrared spectroscopy and post-assembly forensics are also described. The final mode-II fracture toughness measured from precracked AERoBOND specimens was similar to that measured from co-cured laminates indicating that later cure epoxy materials could be a suitable replacement for secondary bonding.

Polymer-matrix composites (PMCs)↗

NASA NTRS2018

Simulating the Effects of Carbon Nanotube Continuity and Interfacial Bonding on Composite Strength and Stiffness

Molecular dynamics simulations of carbon nanotube (CNT) composites, in which the CNTs are continuous across the periodic boundary, overestimate the experimentally measured mechanical properties of CNT composites along the fiber direction. Since the CNTs in these composites are much shorter than the composite dimensions, load must be transferred either directly between CNTs or through the matrix, a mechanism that is absent in simulations of effectively continuous CNTs. In this study, the elastic and fracture properties of high volume fraction discontinuous carbon nanotube/amorphous carbon composite systems were compared to those of otherwise equivalent continuous CNT composites using ReaxFF reactive molecular dynamics simulations. These simulations were used to show how the number of nanotube-matrix interfacial covalent bonds affect composite mechanical properties. Furthermore, the mechanical impact of interfacial bonding was decomposed to reveal its effect on the properties of the CNTs, the interfacial layer of matrix, and the bulk matrix. For the composites with continuous reinforcement, it was found that any degree of interfacial bonding has a negative impact on axial tensile strength and stiffness. This is due to disruption of the structure of the CNTs and interfacial matrix layer by the interfacial bonds. For the discontinuous composites, the modulus was maximized between 4%-7% interfacial bonding and the strength continues to increase up to the highest levels of interfacial bonding studied. Areas of low stress and voids were observed in the simulated discontinuous composites at the ends of the tubes, from which fracture was observed to initiate. Experimental carbon nanotube yarn composites were fabricated and tested. The results were used to illustrate knockdown factors relative to the mechanical performance of the tubes themselves.

Benjamin D Jensen↗

NASA NTRS2010

Probabilistic Simulation for Nanocomposite Fracture

A unique probabilistic theory is described to predict the uniaxial strengths and fracture properties of nanocomposites. The simulation is based on composite micromechanics with progressive substructuring down to a nanoscale slice of a nanofiber where all the governing equations are formulated. These equations have been programmed in a computer code. That computer code is used to simulate uniaxial strengths and fracture of a nanofiber laminate. The results are presented graphically and discussed with respect to their practical significance. These results show smooth distributions from low probability to high.

Chamis, Christos C.↗

NASA NTRS1998

Characterization of Al-Cu-Li Alloy 2090 Near Net Shape Extrusion

Aluminum-lithium (Al-Li) alloys near net shape extrusions are being evaluated for potential application in launch vehicle structures. The objective of this study was to determine tensile and fracture properties, corrosion resistance, and weldability of integrally stiffened panels of Al-Cu-Li alloy 2090 in the T8 temper. The microstructure was pre-dominantly unrecrystallized. Texture analyses revealed the presence of fiber components in the stiffeners and a combination of fiber and rolling components in the skin. Variations in grain morphology and texture through the extruded cross section were correlated with the tensile, fracture, and corrosion behavior. Tensile strengths at room and cryogenic temperatures of the 2090 extrusions were similar to other 2090 product forms and were higher than 2219-T87, the primary structural material in the Space Shuttle external tank; however, ductilities were lower. The fracture resistance of the 2090 extrusion was lower than 2219-T87 plate at room temperature. At cryogenic temperatures, tensile ductility and fracture behavior of the 2090 extrusion were similar to other 2090 product forms but were lower than 2219-T87 plate. The exfoliation and stress corrosion resistance of the 2090 extrusion compared favorably with the characteristics of other 2090 product forms. The weldability and weldment properties of the extrusions were similar to 2090 and 2219 plates.

Birt, M. J.↗

NASA NTRS1989

Effects of aging condition on the fracture toughness of 2XXX and 7XXX series aluminum alloy composites

Results are presented on the effects of matrix aging condition (i.e., matrix temper) on the fracture toughness of 2XXX and 7XXX Al matrix alloys reinforced with SiC particulates, and the results are compared with the mechanical behavior. Fracture toughness testing was conducted on fatigue precracked bend specimens, and fracture surfaces were examined using SEM. Results revealed dramatic differences in the effect of matrix microstructure on the fracture properties of the two composite series. In the 7XXX material, the toughness values decreased from the underaged (UA) condition to the overaged (OA) condition by approximately 40 percent, while in the 2XXX series composite, the effect of matrix microstructure was marginal. In the 7XXX series composites, a transition in fracture mode from particle cracking (in UA) to matrix and linear-interface failure (in OA) was observed, while the 2XXX series composite failed predominantly by particle cracking.

Manoharan, M.↗

NASA NTRS1996

Thermomechanical Property Data Base Developed for Ceramic Fibers

A key to the successful application of metal and ceramic composite materials in advanced propulsion and power systems is the judicious selection of continuous-length fiber reinforcement. Appropriate fibers can provide these composites with the required thermomechanical performance. To aid in this selection, researchers at the NASA Lewis Research Center, using in-house state-of-the-art test facilities, developed an extensive data base of the deformation and fracture properties of commercial and developmental ceramic fibers at elevated temperatures. Lewis' experimental focus was primarily on fiber compositions based on silicon carbide or alumina because of their oxidation resistance, low density, and high modulus. Test approaches typically included tensile and flexural measurements on single fibers or on multifilament tow fibers in controlled environments of air or argon at temperatures from 800 to 1400 C. Some fiber specimens were pretreated at composite fabrication temperatures to simulate in situ composite conditions, whereas others were precoated with potential interphase and matrix materials.

Source record↗

NASA NTRS1989

Thermoplastic matrix composites - Finite-element analysis of mode I and mode II failure specimens

A finite-element analysis was conducted to evaluate the stress distributions within mode I and mode II failure specimens, assuming both isotropic and orthotropic elastic material properties. The effects of anisotropy on both the magnitude and the location of the highest stress concentration at the vicinity of the crack tip are significant. The results from modeling realistic blunt crack tip geometry and resin-rich zones imply that local variations in the microstructure strongly influence the stress state near the crack tip and therefore the measured fracture properties. In addition, the features of a viscoelastic model for thermoplastic matrices are described. This model will be used in future investigations of matrix-dominated failure phenomena.

Bankert, Ray J.↗

NASA NTRS2000

B218 Weld Filler Wire Characterization for Al-Li Alloy 2195

NASA Marshall Space Flight Center, Lockheed Martin Space Systems- Michoud Operations, and McCook Metals have developed an aluminum-copper weld filler wire for fusion welding aluminum lithium alloy 2195. The aluminum-copper based weld filler wire has been identified as B218, a McCook Metals designation. B218 is the result of six years of weld filler wire development funded by NASA, Lockheed Martin, and McCook Metals. The filler wire chemistry was developed to produce enhanced 2195 weld and repair weld mechanical properties over the 4043 aluminum-silicon weld filler wire, which is currently used to weld 2195 on the Super Lightweight External Tank for the NASA Space Shuttle Program. An initial characterization was performed consisting of a repair weld evaluation using B218 and 4043 weld filler wires. The testing involved room temperature and cryogenic repair weld tensile testing along with fracture toughness testing. From the testing, B218 weld filler wire produce enhanced repair weld tensile strength, ductility, and fracture properties over 4043. B218 weld filler wire has proved to be a superior weld filler wire for welding aluminum lithium alloy 2195 over 4043.

Bjorkman, Gerry↗

NASA NTRS1971

The effect of alloy composition on the mechanism of stress corrosion cracking of titanium alloys in aqueous environments

Emphasis has been placed on determining the interrelations among the composition, phase structure, deformation, and fracture properties of the alpha phase in susceptible alpha-beta alloys. The program is divided into two parts: (1) evaluation of the aqueous stress corrosion susceptibility of a series of alloys that contain various alpha-soluble elements; and (2) investigations of the metallurgical aspects of the mechanism of aqueous stress corrosion cracking.

Williams, D. N.↗

NASA NTRS1972

The effect of alloy composition on the mechanism of stress corrosion cracking of titanium alloys in aqueous environments

The effects of alloy composition on the aqueous stress corrosion of titanium alloys were studied with emphasis on determining the interrelations among composition, phase structure, and deformation and fracture properties of the alpha phase in alpha-beta alloys. Accomplishments summarized include the effects of alloy composition on susceptibility, and metallurgical mechanisms of stress-corrosion cracking.

Boyd, J. D.↗

NASA NTRS1972

Analysis of fatigue crack propagation

The correlation between fatigue crack propagation and stress intensity factor is analyzed. When determining fatigue crack propagation rate, a crack increment, delta a, and its corresponding increment in load cycles, delta N, are measured. Fatigue crack propagation must be caused by a shear and/or a normal separation mode. Both of these two processes are discrete if one looks at the atomic level. If the average deformation and fracture properties over the crack increments, delta a, can be considered as homogeneous, if the characteristic discrete lengths of sigma a, if the plastic zone size is small, and if a plate is thick enough to insure a plane strain case, da/dN is proportional to delta K squared. Any deviation of empirical data from this relation must be caused by the fact that one or more of these conditions are not satisfied. The effects of plate thickness and material inhomogeneity are discussed in detail. A shear separation mode of fatigue crack propagation is described and is used to illustrate the effects of material inhomogeneity.

Liu, H. W.↗

NASA NTRS1975

Validation testing of shallow notched round-bar screening test specimens

The capability of shallow-notched, round-bar, tensile specimens for screening critical environments as they affect the material fracture properties of the space shuttle main engine was tested and analyzed. Specimens containing a 0.050-inch-deep circumferential sharp notch were cyclically loaded in a 5000-psi hydrogen environment at temperatures of +70 and -15 F. Replication of test results and a marked change in cyclic life because of temperature variation demonstrated the validity of the specimen type to be utilized for screening tests.

Vroman, G. A.↗

NASA NTRS1982

Strength advantages of chemically polished boron fibers before and after reaction with aluminum

In order to determine their strength potential, the fracture properties of different types of commercial boron fibers were measured before and after application of secondary strengthening treatments. The principal treatments employed were a slight chemical polish, which removed low strength surface flaws, and a heat treatment in oxygen, which contracted the fibers and thereby compressed intrinsic bulk flaws. Those fiber types most significantly strengthened were 200 to 400 micrometers (8 to 16 mil) diameter boron on tungsten fibers produced in a single chemical vapor deposition reactor. The slight polish increased average tensile strenghts from 3.4 to 4.4 CN/m2 (500 to 640 ksi) and reduced coefficients of variation from about 15 to 3 percent. The oxygen heat treatment plus slight polish further improved average strengths to 5.5 GN/m2 (800 ksi) with coefficients near 3 percent. To ascertain whether these excellent properties could be retained after fabrication of B/Al composites, as produced and polished 203 micrometers (8 mil) fibers were thinly coated with aluminum, heat treated at B/Al fabrication temperatures, and then tested in tension and flexure at room temperature. The pre-polished fibers were observed to retain their superior strengths to higher temperatures than the as-produced fibers even though both were subjected to the same detrimental reaction with aluminum.

Dicarlo, J. A.↗

NASA NTRS1982

Mechanics aspects of NDE by sound and ultrasound

Nondestructive evaluation (NDE) is considered as a means to detect the energy release mechanism of defects and the interaction of microstructures within materials with sound waves and/or ultrasonic waves. Ultrasonic inspection involves the frequency range 20 kHz-1 GHz with amplitudes depending on the sensitivity of the test instrumentation. Pulse echo systems are most frequently used in NDE. Information is extracted from the signals through measurements of the signal velocity, attenuation, the acoustic emission when stress is applied, and calculation of the acoustoelastic coefficients. Fracture properties, tensile and shear strengths, the interlaminar shear strength, the cohesive strength, yield and impact strengths, the hardness, and the residual stress can be assayed by ultrasonic methods. Finally, attention is given to analytical treatment of the derived data, with mention given to transition matrix, integral equation, and eigenstrain approaches.

Fu, L. S.↗

NASA NTRS1983

A surface analytical examination of Stringer particles in Al-Li-Cu alloys

A surface analytical examination of powder metallurgy processed Al-Li-Cu alloys was conducted. The oxide stringer particles often found in these alloys was characterized. Particle characterization is important to more fully understand their impact on the stress corrosion and fracture properties of the alloy. The techniques used were SIMS (Secondary Ion Mass Spectroscopy) and SAM (Scanning Auger Microscopy). The results indicate that the oxide stringer particles contain both Al and Li with relatively high Li content and the Li compounds may be associated with the stringer particles, thereby locally depleting the adjacent matrix of Li solute.

Larson, L. A.↗

NASA NTRS1984

A surface-analytical examination of stringer particles in aluminum-lithium-copper alloys

A surface analytical examination of powder metallurgy processed Al-Li-Cu alloys was conducted. The oxide stringer particles often found in these alloys are characterized. Particle characterization is important to more fully understand their impact on the stress corrosion and fracture properties of the alloy. The techniques used where SIMS (Secondary Ion Mass Spectroscopy) and SAM (Scanning Auger Microscopy). The results indicate that the oxide stringer particles contain both Al and LI with relatively high Li content and the Li compounds may be associated with the stringer particles, thereby locally depleting the adjacent matrix of Li solute.

Larson, L. A.↗

NASA NTRS1987

Evaluation of GaAs Fracture Mechanics

Report provides data on fracture properties of single-crystal GaAs. Data required for design of reliable GaAs solar cells and modules. Aids design of solar cells.

Chen, C. P.↗

NASA NTRS1986

Testing techniques for mechanical characterization of rapidly solidified materials

Mechanical property testing techniques are reviewed for rapidly solidified materials. Mechanical testing of rapidly solidified materials is complicated by the fact that in most cases at least one dimension of the material is very small (less than 100 microns). For some geometries, i.e., powder or thin surface layers, microhardness is the only feasible mechanical test. The ribbon geometry which is obtained by the melt-spinning method, however, has been used for a variety of mechanical property measurements including elastic properties, tensile properties, fracture toughness, creep, and fatigue. These techniques are described with emphasis placed on the precautions required by the restricted geometry of rapidly solidified specimens.

Koch, C. C.↗