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NASA NTRS2010

Determining Shear Stress Distribution in a Laminate

A "simplified shear solution" method approximates the through-thickness shear stress distribution within a composite laminate based on an extension of laminated beam theory. The method does not consider the solution of a particular boundary value problem; rather, it requires only knowledge of the global shear loading, geometry, and material properties of the laminate or panel. It is thus analogous to lamination theory in that ply-level stresses can be efficiently determined from global load resultants at a given location in a structure and used to evaluate the margin of safety on a ply-by-ply basis. The simplified shear solution stress distribution is zero at free surfaces, continuous at ply boundaries, and integrates to the applied shear load. The method has been incorporated within the HyperSizer commercial structural sizing software to improve its predictive capability for designing composite structures. The HyperSizer structural sizing software is used extensively by NASA to design composite structures. In the case of through-thickness shear loading on panels, HyperSizer previously included a basic, industry-standard, method for approximating the resulting shear stress distribution in sandwich panels. However, no such method was employed for solid laminate panels. The purpose of the innovation is to provide an approximation of the through-thickness shear stresses in a solid laminate given the through-thickness shear loads (Qx and Qy) on the panel. The method was needed for implementation within the HyperSizer structural sizing software so that the approximated ply-level shear stresses could be utilized in a failure theory to assess the adequacy of a panel design. The simplified shear solution method was developed based on extending and generalizing bi-material beam theory to plate-like structures. It is assumed that the through-thickness shear stresses arise due to local bending of the laminate induced by the through-thickness shear load, and by imposing equilibrium both vertically and horizontally, the through-thickness shear stress distribution can be calculated. The resulting shear stresses integrate to the applied shear load, are continuous at the ply interfaces, and are zero at the laminate-free surfaces. If both Qx and Qy shear loads are present, it is assumed that they act independently and that their effects can be superposed. The calculated shear stresses can be rotated within each ply to the principal material coordinates for use in a ply-level failure criterion. The novelty of the simplified shear solution method is its simplicity and the fact that it does not require solution of a particular boundary value problem. The advantages of the innovation are that an approximation of the though-thickness shear stress distribution can be quickly determined for any solid laminate or solid laminate region within a stiffened panel.

Bednarcyk, Brett A.↗

NASA NTRS2012

Composite Laminate With Coefficient of Thermal Expansion Matching D263 Glass

The International X-ray Observatory project seeks to make an X-ray telescope assembly with 14,000 flexible glass segments. The glass used is commercially available SCHOTT D263 glass. Thermal expansion causes the mirror to distort out of alignment. A housing material is needed that has a matching coefficient of thermal expansion (CTE) so that when temperatures change in the X-ray mirror assembly, the glass and housing pieces expand equally, thus reducing or eliminating distortion. Desirable characteristics of this material include a high stiffness/weight ratio, and low density. Some metal alloys show promise in matching the CTE of D263 glass, but their density is high compared to aluminum, and their stiffness/weight ratio is not favorable. A laminate made from carbon fiber reinforced plastic (CFRP) should provide more favorable characteristics, but there has not been any made with the CTE matching D263 Glass. It is common to create CFRP laminates of various CTEs by stacking layers of prepreg material at various angles. However, the CTE of D263 glass is 6.3 ppm/ C at 20 C, which is quite high, and actually unachievable solely with carbon fiber and resin. A composite laminate has been developed that has a coefficient of thermal expansion identical to that of SCHOTT D263 glass. The laminate is made of a combination of T300 carbon fiber, Eglass, and RS3C resin. The laminate has 50% uni-T300 plies and 50% uni-E-glass plies, with each fiber-layer type laid up in a quasi-isotropic laminate for a total of 16 plies. The fiber volume (percent of fiber compared to the resin) controls the CTE to a great extent. Tests have confirmed that a fiber volume around 48% gives a CTE of 6.3 ppm/ C. This is a fairly simple composite laminate, following well established industry procedures. The unique feature of this laminate is a somewhat unusual combination of carbon fiber with E-glass (fiberglass). The advantage is that the resulting CTE comes out to 6.3 ppm/ C at 20 C, which matches D263 glass. The trick with this laminate is to establish the proper fiber volume to get the desired CTE. Laminates were made with several different fiber volumes and coupons were tested to establish the relationship between fiber volume and CTE. Testing proved that fiber volume should be about 48%.

Robinson, David↗

DOE OSTI2018

High expression of A-type lamin in the leading front is required for Drosophila thorax closure

Highlights: • Lamin C expression is high at the leading front of the closing tissue in pupal notum. • Lamin C is required for the coordinated movement of the leading front. • The closure defect by Lamin C knockdown correlates with insufficient F-actin formation. Tissue closure involves the coordinated unidirectional movement of a group of cells without loss of cell–cell contact. However, the molecular mechanisms controlling the tissue closure are not fully understood. Here, we demonstrate that Lamin C, the sole A-type lamin in Drosophila, contributes to the process of thorax closure in pupa. High expression of Lamin C was observed at the leading front of the migrating wing imaginal discs. Live imaging analysis revealed that knockdown of Lamin C in the thorax region affected the coordinated movement of the leading front, resulting in incomplete tissue fusion required for formation of the adult thorax. The closure defect due to knockdown of Lamin C correlated with insufficient accumulation of F-actin at the front. Our study indicates a link between A-type lamin and the cell migration behavior during tissue closure.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2024

Investigation of the notch sensitivity of tailorable long fiber discontinuous prepreg composite laminates

Tailorable discontinuous fiber composite laminates provide relative formability beyond that of continuous fiber laminates, while achieving improved mechanical performance over comparable stochastic systems. Here, in this work, the notch sensitivity of engineered prepreg platelet molded composite (PPMC) laminates is investigated using the open-hole tension (OHT) test and compared to available data for stochastic PPMCs and continuous fiber laminates made with the same material. The press-formed thermoplastic composites (AS4/PEKK) were molded with a quasi-isotropic stacking sequence. The discontinuous PPMC laminate was found to be notch insensitive with OHT strengths ranging from 145.4 MPa (CV $=$ 7%) for d/w $=$ 0.5 to 229.3 MPa (CV $=$ 9%) for d/w $=$ 0.25. The highly ordered meso-structure of the engineered PPMC laminate yields comparatively excellent mechanical properties for relatively thin laminates in contrast to stochastic systems. Both net- and gross-section failures were observed for d/w $=$ 0.25, which suggests that the engineered PPMC laminates studied here maintain a degree of inherent, internal stress concentrations that compete with those caused by geometric features such as a circular hole. Computational simulations of the OHT tests with explicitly represented platelets were found to be in good agreement with experimental measurements. The progressive failure analysis was used to conduct a numerical investigation of the stacking sequence and platelet meso-morphology.

36 MATERIALS SCIENCE↗

NASA NTRS1974

A theory for predicting composite laminate warpage resulting from fabrication

Linear laminate theory is used with the moment-curvature relationship to derive equations for predicting end deflections due to warpage without solving the coupled fourth-order partial differential equations of the plate. Composite micro- and macrohyphenmechanics are used with laminate theory to assess the contribution of factors such as ply misorientation, fiber migration, and fiber and/or void volume ratio nonuniformity on the laminate warpage. Using these equations, it was found that a 1 deg error in the orientation angle of one ply was sufficient to produce warpage end deflection equal to two laminate thicknesses in a 10 inch by 10 inch laminate made from 8 ply Mod-I/epoxy. Using a sensitivity analysis on the governing parameters, it was found that a 3 deg fiber migration or a void volume ratio of three percent in some plies is sufficient to produce laminate warpage corner deflection equal to several laminate thicknesses. Tabular and graphical data are presented which can be used to identify possible errors contributing to laminate warpage and/or to obtain an a priori assessment when unavoidable errors during fabrication are anticipated.

Chamis, C. C.↗

NASA NTRS1981

The effect of lamination-induced stresses on fatigue damage development at internal flaws

The effects of stresses induced by the lamination of off-axis plies to O-deg lamina on the development of damage during the fatigue loading of the O-deg plies are discussed. The transverse normal stresses in the plane of the laminae and the laminate created by the laminating constraints when an axial force is applied to the laminate are calculated in terms of a differential Poisson ratio between the ply in question in the unconstrained and constrained states, and significant differences in the constraint environments of an unnotched specimen joined to plies of 45 and 90 deg inclination are noted which correspond to an increase in longitudinal splitting in the 90 deg case and a marked decrease in longitudinal splitting in the 45 deg case. If a notch is present, shear and crack-opening damage is found to be very effectively suppressed in 45-deg laminates, and less so in the 90-deg case. It is pointed out that whereas the 45-deg laminate represents the least damage situation, it does not have the greatest notched strength. It is concluded that an understanding and prediction of damage development in laminates requires knowledge of the stress fields caused by the lamination constraints.

Reifsnider, K. L.↗

NASA NTRS1984

Compression failure characteristics of + or - 45-deg-dominated laminates with a circular hole or impact damage

An investigation of the compression failure characteristics of + or - 45-deg-dominated laminates with a circular hole or impact damage was conducted. Graphite-epoxy laminates consisting of all + or - 45-deg plies and of + or - 45-deg and 90-deg plies were evaluated. Inplane shearing between the fibers and matrix (i.e., matrix shearing) was found to be the primary compression failure mechanism for an all + or - 45-deg laminate with a hole. The failure mechanism for the + or 45-deg-dominated laminates with a hole appeared to be a combination of delamination and matrix shearing. The compression failure stresses and strains for both the all + or - 45-deg laminate and the + or - 45-deg-dominated laminates were unaffected by impact damage at an energy level of 5.5 J when compared to results for undamaged control specimens. The failure stresses and strains for all laminates with impact damage at an energy level of 17.0 J or of 34.3 J were significantly lower than the corresponding data for the undamaged control specimens. The failure stresses and strains for these impact-damaged specimens were independent of the percentage of 90-deg plies in the laminate.

Shuart, M. J.↗

NASA NTRS1985

Role of delamination and damage development on the strength of thick notched laminates

A large, comprehensive program is being conducted at Virginia Tech to study the effect of laminate thickness on the fracture strength of notched laminated composites. Part of this program has been the study of the chracteristics and development of subcritical crack-tip damage prior to failure. The study has concentrated on the center-cracked tension specimen geometry. Subcritical crack-tip damage has been studied using enhanced X-ray radiography and the laminate deply technique. This paper examines he role that delamination plays in affecting the fracture of (0/+ or - 45/90)ns and (0/+ or - 45)ns laminates at various values of n. The study has found that delaminations do occur in thin laminates (n = 1) and affect the strength of the laminate. However, in thick laminates such as (0/+ or 45)90ns, and (0/+ or - 45)20s, there is sufficient constraint to prevent delaminations from occurring in the interior region of he specimen. The final fracture surface is uniform in the interior and self-similar (collinear with the original starter notch), with 'shear-lip' type damage in the form of delaminations and matrix cracking in the first several plies at the surface. These differences in the type of fracture of the thin and thick laminates greatly affect the fracture strength.

Harris, C. E.↗

NASA NTRS1988

Thermal cycling effects on the dimensional stability of P75 and P75-T300 (fabric) hybrid graphite/epoxy laminates

The response of cross-ply P75/934 laminates and hybrid laminates consisting of P75/934 unidirectional tape and T300/934 woven fabric were compared for temperature exposures between + and - 250 F up to a maximum of 250 cycles. The properties monitored included microcrack density, coefficient of thermal expansion (CTE), residual strain, and tensile modulus. Hybrid laminates, with stiffnesses and CTE's comparable to P75/934 cross-ply laminates, demonstrated significantly improved thermal cycling stability in one direction. The hybrid laminates also had predicted longitudinal properties comparable to low angle, off-axis P75/934 configurations, but had significantly higher predicted transverse strengths. T300 Gr/Ep plain-weave fabric laminates were shown to be much less susceptible to thermal cycling damage than T300 Gr/Ep cross-ply laminates. None of the laminates tested exhibited any significant changes in tensile modulus after thermal cycling.

Bowles, David E.↗

NASA NTRS1989

An analytical and experimental investigation of edge delamination in laminates subjected to tension, bending, and torsion

An integrated two-dimensional finite element was developed to calculate interlaminar stresses and strain energy release rates for the study of delamination in composite laminates subjected to uniaxial tension, bending, and torsion loads. Addressed are the formulation, implementation, and verification of the model. Parametric studies were conducted on the effect of Poisson's ratio mismatch between plies and the stacking sequence on interlaminar stress, and on the effect of delamination opening height and delamination length, due to bending, on strain energy release rate for various laminates. A comparison of strain energy release rates in all-graphite and graphite/glass hybrid laminates is included. The preliminary results of laminates subjected to torsion are also included. Fatigue tension tests were conducted on Mode 1 and mixed mode edge-delamination coupons to establish the relationship between fatigue load vs. onset of delamination cycle. The effect on the fatigue delamination onset of different frequencies (1 and 5 Hz) was investigated for glass, graphite,and their hybrid laminates. Although a 20 percent increase in the static onset-of-delamination strength and a 10 percent increase in ultimate strength resulted from hybridizing the all-graphite laminate with a 90 deg glass ply, the fatigue onset is lower in the hybrid laminate than in the all-graphite laminate.

Chan, Wen S.↗

NASA NTRS1992

Compression response of thick layer composite laminates with through-the-thickness reinforcement

Compression and compression-after-impact (CAI) tests were conducted on seven different AS4-3501-6 (0/90) 0.64-cm thick composite laminates. Four of the seven laminates had through-the-thickness (TTT) reinforcement fibers. Two TTT reinforcement methods, stitching and integral weaving, and two reinforcement fibers, Kevlar and carbon, were used. The remaining three laminates were made without TTT reinforcements and were tested to establish a baseline for comparison with the laminates having TTT reinforcement. Six of the seven laminates consisted of nine thick layers whereas the seventh material was composed of 46 thin plies. The use of thick-layer material has the potential for reducing structural part cost because of the reduced part count (layers of material). The compression strengths of the TTT reinforced laminates were approximately one half those of the materials without TTT reinforcements. However, the CAI strengths of the TTT reinforced materials were approximately twice those of materials without TTT reinforcements. The improvement in CAI strength is due to an increase in interlaminar strength produced by the TTT reinforcement. Stitched laminates had slightly higher compression and CAI strengths than the integrally woven laminates.

Farley, Gary L.↗

NASA NTRS1993

Probabilistic and structural reliability analysis of laminated composite structures based on the IPACS code

Probabilistic predictions based on the Integrated Probabilistic Assessment of Composite Structures (IPACS) code are presented for the material and structural response of unnotched and notched, 1M6/3501-6 Gr/Ep laminates. Comparisons of predicted and measured modulus and strength distributions are given for unnotched unidirectional, cross-ply, and quasi-isotropic laminates. The predicted modulus distributions were found to correlate well with the test results for all three unnotched laminates. Correlations of strength distributions for the unnotched laminates are judged good for the unidirectional laminate and fair for the cross-ply laminate, whereas the strength correlation for the quasi-isotropic laminate is deficient because IPACS did not yet have a progressive failure capability. The paper also presents probabilistic and structural reliability analysis predictions for the strain concentration factor (SCF) for an open-hole, quasi-isotropic laminate subjected to longitudinal tension. A special procedure was developed to adapt IPACS for the structural reliability analysis. The reliability results show the importance of identifying the most significant random variables upon which the SCF depends, and of having accurate scatter values for these variables.

Sobel, Larry↗

NASA NTRS1992

Effects of changes in composite lamina properties on laminate coefficient of thermal expansion

An analytical study of the effects of changes in composite lamina properties on the laminate coefficient of thermal expansion, CTE, has been made. Low modulus graphite/epoxy (T300/934) and high modulus graphite/epoxy (P75/934, P100/934, P120/934), graphite/aluminum (P100/Al), and graphite/glass (HMS/Gl) composite materials were considered in quasi-isotropic and near-zero CTE laminate configurations. The effects of changes in lamina properties on the laminate CTE strongly depend upon the type of composite material as well as the laminate configuration. A 10 percent change in the lamina transverse CTE resulted in changes as large as 0.22 ppm/C in the laminate CTE of a quasi-isotropic Gr/934 laminates. No significant differences were observed in the sensitivities of the laminate CTEs of the P100/934 and P120/934 composite materials due to identical changes in lamina properties. Large changes in laminate CTE can also result from measured temperature and radiation effects on lamina properties.

Tompkins, Stephen S.↗

NASA NTRS1995

Effects of through-the-thickness stitching on impact and interlaminar fracture properties of textile graphite/epoxy laminates

This study investigated the effects of through-the-thickness stitching on impact damage resistance, impact damage tolerance, and mode I and mode II fracture toughness of textile graphite/epoxy laminates. Uniweave resin-transfer-molded 48 ply graphite/epoxy (AS4/3501-6) laminates were stitched with Kevlar and glass yarns of different linear densities and stitch spacings. Delaminations were implanted during processing to simulate impact damage. Sublaminate buckling tests were performed to determine the effects of stitching on the compressive strength. The results showed outstanding improvements of up to 400 percent in the compression strength over the unstitched laminates. In impact and static indentation tests the onset of damage occurred at the same level, but the extent of damage was less in stitched laminates. Mode I fracture toughness of 24 ply Uniweave unidirectional (AS4/3501-6) stitched laminates was measured by conducting double-cantilever-beam tests. The critical strain energy release rate (G(sub Ic)) was found to be up to 30 times higher than the unstitched laminates. Mode II fracture toughness of the Uniweave laminates was measured by performing end-notched-flexure tests. Two new methods to compute the apparent G(sub IIc) are presented. The apparent G(sub IIc) was found to be at least 5-15 times higher for the stitched laminates.

Sharma, Suresh K.↗

NASA NTRS2013

Normalization of Impact Energy by Laminate Thickness for Compression After Impact Testing

The amount of impact energy used to damage a composite laminate is a critical parameter when assessing residual strength properties. The compression after impact (CAI) strength of impacted laminates is dependent upon how thick the laminate is and this has traditionally been accounted for by normalizing (dividing) the impact energy by the laminate's thickness. However, when comparing CAI strength values for a given lay-up sequence and fiber/resin system, dividing the impact energy by the specimen thickness has been noted by the author to give higher CAI strength values for thicker laminates. A study was thus undertaken to assess the comparability of CAI strength data by normalizing the impact energy by the specimen thickness raised to a power to account for the higher strength of thicker laminates. One set of data from the literature and two generated in this study were analyzed by dividing the impact energy by the specimen thickness to the 1, 1.5, 2, and 2.5 powers. Results show that as laminate thickness and damage severity decreased, the value which the laminate thickness needs to be raised to in order to yield more comparable CAI data increases.

Nettles, A. T.↗

DOE OSTI2014

Highly-laminated, high-saturation-flux-density, magnetic cores for on-chip inductors in power converter applications

The objective of this project is development of a manufacturing process to realize thick highly-laminated metallic magnetic cores with suppressed eddy current losses for power applications and demonstration of integrated magnetic components using the process. The continual reduction in size and increase in functionality of portable electronic devices drives the development of ultracompact electrical power converters and therefore their associated inductors, which typically occupy the largest volume within the converter. This inductor size reduction can be achieved by increasing both the converter switching frequency as well as inductor operating flux density by utilizing appropriate magnetic core materials. Magnetically soft metallic alloys (e.g., NiFe and CoNiFe) are good core material candidates due to their superior magnetic properties (e.g., high saturation flux density and low coercivity) compared to conventional ferrite. However, to minimize eddy current losses, the core thickness is limited to the skin depth (typically less than 3 µm for 10 MHz operation); cores of this thickness are likely insufficient for handling high power (> 10W). Therefore, there is great interest in the development of highly-laminated metallic alloy cores with single lamination thickness in the sub-micron range to achieve suppressed eddy-current losses and high power handling capacity simultaneously. During the project, highly-laminated metallic alloy cores comprising up to 2000 layers of permalloy (Ni 80 Fe 20 ) or CoNiFe materials with single lamination thickness less than 1 µm have been fabricated based on automated multilayer electrodeposition technology compatible with CMOS manufacturing. The developed highly-laminated metallic cores preserve the high saturation flux density and low coercivity characteristics of metallic alloys, while suppressing eddy-current losses less than 1 W/cm3 at operation flux density of 0.5 T and frequency over 1 MHz. The developed highly-laminated metallic alloy cores have been further integrated into microfabricated windings to realize compact, on-chip inductors. Utilizing CMOS-compatible integration techniques, circular (toroid) and bar-shape (solenoid) microinductors have been fabricated exhibiting a constant inductance higher than 1 µH up to 50 MHz with peak quality factor as high as 35 at 5 MHz. The microfabricated inductor with highly-laminated core was tested in a power converter and demonstrated a converter efficiency of 93% at 5.5 MHz and 42 W under 100V input and 35V output operation.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1993

The major nucleoside triphosphatase in pea (Pisum sativum L.) nuclei and in rat liver nuclei share common epitopes also present in nuclear lamins

The major nucleoside triphosphatase (NTPase) activities in mammalian and pea (Pisum sativum L.) nuclei are associated with enzymes that are very similar both biochemically and immunochemically. The major NTPase from rat liver nuclei appears to be a 46-kD enzyme that represents the N-terminal portion of lamins A and C, two lamina proteins that apparently arise from the same gene by alternate splicing. Monoclonal antibody (MAb) G2, raised to human lamin C, both immunoprecipitates the major (47 kD) NTPase in pea nuclei and recognizes it in western blot analyses. A polyclonal antibody preparation raised to the 47-kD pea NTPase (pc480) reacts with the same lamin bands that are recognized by MAb G2 in mammalian nuclei. The pc480 antibodies also bind to the same lamin-like bands in pea nuclear envelope-matrix preparations that are recognized by G2 and three other MAbs known to bind to mammalian lamins. In immunofluorescence assays, pc480 and anti-lamin antibodies stain both cytoplasmic and nuclear antigens in plant cells, with slightly enhanced staining along the periphery of the nuclei. These results indicate that the pea and rat liver NTPases are structurally similar and that, in pea nuclei as in rat liver nuclei, the major NTPase is probably derived from a lamin precursor by proteolysis.

Non-NASA Center↗

DOE OSTI2026

Ultrafast (1‐5 sec) Lamination of Perovskite Solar Cells With Self‐Encapsulation Using Rapid Joule Heating

Perovskite solar cells (PSCs) are traditionally fabricated using sequential layer‐by‐layer deposition, in which each layer of the device is processed on top of the preceding layer. This constrains the processing techniques and selection of transport layer materials that can be used in the solar cell. To overcome these challenges, two half‐cells can be processed independently and then diffusion‐bonded through a lamination process. However, current lamination processes for perovskite solar cells suffer from relatively long process times, which can limit throughput when moving toward high‐volume manufacturing. In this study, a custom platform was designed for rapid‐joule heating of perovskite materials and devices. This enabled more than a 99% reduction in lamination time from 26 min to 1 s. Perovskite samples that were laminated in 1 s exhibited comparable values of percent bonded area, interfacial toughness, grain domain size, and X‐ray diffraction spectra to those laminated in greater than 10 min. As a proof‐of‐concept, 18.3% efficient devices were successfully laminated in 5 s. A transient heat transfer model was developed to describe the relationship between the perovskite temperature and the electrical power supplied to the heaters, establishing a baseline for predicting processing conditions in large‐scale manufacturing systems. Ultra‐fast lamination provides a pathway toward scalable roll‐to‐roll or sheet‐to‐sheet manufacturing of PSCs.

heat transfer↗