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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2007

Hypervelocity Impact (HVI): WLE High Fidelity Specimen Fg(RCC)-2 - Volume 6

During 2003 and 2004, the Johnson Space Center's White Sands Testing Facility in Las Cruces, New Mexico conducted hypervelocity impact tests on the space shuttle wing leading edge. Hypervelocity impact tests were conducted to determine if Micro-Meteoroid/Orbital Debris impacts could be reliably detected and located using simple passive ultrasonic methods. The objective of Target Fg(RCC)-2 was to study hypervelocity impacts through the reinforced carbon-carbon (RCC) panels of the Wing Leading Edge. Fiberglass was used in place of RCC in the initial tests. Impact damage was detected using lightweight, low power instrumentation capable of being used in flight.

Gorman, Michael R.↗
NASA NTRS1982

Lacquer Reveals Impact Damage in Composites

Brittle lacquer unveils effects normally visible only by ultrasonic inspection. Laquer coating measures spread of cracking and delamination in graphite/epoxy panels subjected to cyclic compression loads after impact damage. Test specimen is coated with lacquer on side opposite surface at which projectile will be fired. Spalled area shows effect of impact without removing specimen from test fixture.

Rhodes, M. D.↗
NASA NTRS1987

A nondestructive technique for predicting the strength remaining in filament wound composites subjected to low-level impact

A model for predicting the fracture strength of homogeneous materials is proposed. Impacted FWC samples were evaluated using ultrasonic testing and an X-ray dye penetration method. The ability of the model to measure fracture strength was also examined. The relation between attenuation and velocity measurements is studied. It is observed that the X-ray method is not useful for predicting fracture strength because the dye could not penetrate the matrix. It is noted that fracture strength predictions derived from the fracture mechanical model and the ultrasonic measurements correlate well with actual measured fracture strengths.

Madaras, E. I.↗
NASA NTRS2007

Hypervelocity Impact (HVI): WLE Small-Scale Fiberglass Panel Flat Multi-Layer Targets A-1, A-2, and B-1 - Volume 2

During 2003 and 2004, the Johnson Space Center's White Sands Testing Facility in Las Cruces, New Mexico conducted hypervelocity impact tests on the space shuttle wing leading edge. Hypervelocity impact tests were conducted to determine if Micro-Meteoroid/Orbital Debris impacts could be reliably detected and located using simple passive ultrasonic methods. The objective of Targets A-1, A-2, and B-2 was to study hypervelocity impacts through multi-layered panels simulating Whipple shields on spacecraft. Impact damage was detected using lightweight, low power instrumentation capable of being used in flight.

Gorman, Michael R.↗
NASA NTRS2017

High Speed Thermal Imaging on Ballistic Impact of Triaxially Braided Composites

Ballistic impact experiments were performed on triaxially braided polymer matrix composites to study the heat generated in the material due to projectile velocity and penetration damage. Quantifying the heat generation phenomenon is crucial for attaining a better understanding of composite behavior and failure under impact loading. The knowledge gained can also be used to improve physics-based models which can numerically simulate impact of composites. Triaxially braided (0/+60/-60) composite panels were manufactured with T700S standard modulus carbon fiber and two epoxy resins. The PR520 (toughened) and 3502 (untoughened) resin systems were used to make different panels to study the effects of resin properties on temperature rise. Ballistic impact tests were conducted on these composite panels using a gas gun, and different projectile velocities were applied to study the effect on the temperature results. Temperature contours were obtained from the rear surface of the panel during the test through a high speed, infrared (IR) thermal imaging system. The contours show that high temperatures were locally generated and more pronounced along the axial tows for the T700S/PR520 composite specimens; whereas, tests performed on T700S/3502 composite panels using similar impact velocities demonstrated a widespread area of lower temperature rises. Nondestructive, ultrasonic C-scan analyses were performed to observe and verify the failure patterns in the impacted panels. Overall, the impact experimentation showed temperatures exceeding 525 K (485degF) in both composites which is well above the respective glass transition temperatures for the polymer constituents. This expresses the need for further high strain rate testing and measurement of the temperature and deformation fields to fully understand the complex behavior and failure of the material in order to improve the confidence in designing aerospace components with these materials.

thermal imaging↗
NASA NTRS2007

Hypervelocity Impact (HVI): Tile Small Targets A-1, Ag-1, B-1, and Bg-1 - Volume 8

During 2003 and 2004, the Johnson Space Center's White Sands Testing Facility in Las Cruces, New Mexico conducted hypervelocity impact tests on the space shuttle wing leading edge. Hypervelocity impact tests were conducted to determine if Micro-Meteoroid/Orbital Debris impacts could be reliably detected and located using simple passive ultrasonic methods. The objective of Targets A-1, Ag-1, B-1, and Bg-1 was to study hypervelocity impacts on the reinforced Shuttle Heat Shield Tiles of the Wing. Impact damage was detected using lightweight, low power instrumentation capable of being used in flight.

Gorman, Michael R.↗
NASA NTRS1991

Quantitative nondestructive evaluation of materials and structures

An experimental investigation was undertaken to quantify damage tolerance and resistance in composite materials impacted using the drop-weight method. Tests were conducted on laminates of several different carbon-fiber composite systems, such as epoxies, modified epoxies, and amorphous and semicrystalline thermoplastics. Impacted composite specimens were examined using destructive and non-destructive techniques to establish the characteristic damage states. Specifically, optical microscopy, ultrasonic, and scanning electron microscopy techniques were used to identify impact induced damage mechanisms. Damage propagation during post impact compression was also studied.

Smith, Barry T.↗
NASA NTRS2019

Impact Damage Tolerance of Composite Laminates with Through-The-Thickness Stitches

The ability of through-the-thickness stitches to contain damage during a low-velocity impact event and increase the residual strength of stitched panels was investigated in this research. The impact response, spread of interlaminar delaminations, dent depth, surface damage, and static residual strength after impact were studied for carbon-epoxy specimens fabricated from HTS40 TohoTenax standard modulus fibers, stitched together with Vectran 1200 denier thread and infused with API 1078 resin after through-the-thickness stitching. Three different stitch patterns were used to explore the ability to arrest impact damage during and after impact. Simply supported boundary conditions were maintained during the impact testing. Non-destructive evaluations were performed using ultrasonic C-scans and X-ray computed tomography (CT) imaging to determine the shape, size, and location of delaminations. Results indicate that while the dynamic response during the impact event was almost the same for the unstitched specimens and all stitch patterns considered, the extent of delamination and the compression strength after impact varied greatly. For both the 60 J and 80 J impact energies, the delamination area was significantly less for the stitched specimens than for the unstitched specimens, but the range of delamination areas among the stitch patterns was much larger for the lower impact energy than for the greater impact energy. Similarly, while the presence of stitching influenced the compression after impact strength, the strength values for all stitch patterns were very similar. These results are a step toward quantifying the influence of through-the-thickness stitching.

Ranatunga, Vipul↗
NASA NTRS1992

Characterization of damage modes in impacted thermoset and thermoplastic composites

Composite materials remain extremely vulnerable to out-of-plane impact loads, which may lead to severe losses in strength and stiffness. Impact induced damage is often a complex mixture of transverse cracks, delaminations and fiber failures. An experimental investigation was undertaken to quantify damage tolerance and resistance in composite materials impacted using the drop-weight method. Tests were conducted on laminates of several different carbon-fiber composite systems such as epoxies, modified epoxies, and amorphous and semicrystalline thermoplastics. In this paper, impacted composite specimens have been examined using destructive and nondestructive techniques to establish the characteristic damage states. Specifically, optical microscopy, ultrasonic and scanning electron microscopy techniques have been used to identify impact induced damage mechanisms. Damage propagation during post impact compression was also studied.

Srinivasan, K.↗
NASA NTRS1984

Pulmonary artery location during microgravity activity: Potential impact for chest-mounted Doppler during space travel

Doppler, or ultrasonic, monitoring for pain manifestations of decompression sickness (the bends) is accomplished by placing a sensor on the chest over the pulmonary artery and listening for bubbles. Difficulties have arisen because the technician notes that the pulmonary artery seems to move with subject movement in a one-g field and because the sensor output is influenced by only slight degrees of sensor movement. This study used two subjects and mapped the position of the pulmonary artery in one-g, microgravity, and two-g environments using ultrasound. The results showed that the pulmonary artery is fixed in location in microgravity and not affected by subject position change. The optimal position corresponded to where the Doppler signal is best heard with the subject in a supine position in a one-g environment. The impact of this result is that a proposed multiple sensor array on the chest proposed for microgravity use may not be necessary to monitor an astronaut during extravehicular activities. Instead, a single sensor of approximately 1 inch diameter and mounted in the position described above may suffice.

Hadley, A. T., III↗
NASA NTRS1993

Indentation-flexure and low-velocity impact damage in graphite epoxy laminates

Static indentation-flexure and low-velocity impact tests were performed on quasi-isotropic and cross-ply graphite/epoxy composite laminates. The load-deflection relations in static tests and impact force history in impact tests were recorded. The damage was assessed by using ultrasonic C-scanning and photo-micrographic techniques. Some features of the static behavior were explained by simple analytical models. A good correlation existed between the load-deflection curves for static and impact loading. It was found that results from a few static indentation-flexure tests can be used to predict the impact force history and delamination radius in composite laminates due to low-velocity impact.

Kwon, Young S.↗
NASA NTRS1992

Indentation-flexure and low-velocity impact damage in graphite/epoxy laminates

Static indentation and low velocity impact tests were performed on quasi-isotropic and cross ply graphite/epoxy composite laminates. The load deflection relations in static tests and impact force history in the impact tests were recorded. The damage was assessed by using ultrasonic C-scanning and photomicrographic techniques. The static behavior of the laminates and damage progression during loading, unloading, and reloading were explained by a simple plate delamination model. A good correlation existed between the static and impact responses. It was found that results from a few static indentation-flexture tests can be used to predict the response and damage in composite laminates due to a class of low velocity impact events.

Kwon, Young S.↗
NASA NTRS2012

NDT and SHM of Carbon Fiber Composites using Linear Drive MWM-Arrays

Carbon fiber composites are used in a wide range of structural applications due to their excellent specific strength and stiffness. However, the anisotropic mechanical and electrical properties associated with the fibers within each composite layer present challenges, and opportunities, for Nondestructive Testing (NDT) methods used to characterize and assess the structure condition. This includes composite condition after manufacture (such as fiber orientation and density, porosity, delamination, and bond strength) and during usage (such as damage from impact, fiber breakage, thermal exposure or applied stress). Ultrasonic and thermographic methods can address some of these challenges, but eddy current methods provide an alternative method for composite structures that contain a conducting material, such as carbon fibers or a metallic liner. This presentation reviews recent advances in the development of eddy current sensors and arrays for carbon fiber composite NDT and Structural Health Monitoring (SHM) applications. The focus is on eddy current sensor constructs with linear drive windings, such as MWM -Arrays, that induce currents primarily within the linear fibers of the composite. By combining this type of sensor construct with micromechanical models that relate composite constituent properties to measurable sensor responses, insight is obtained into the volumetric distribution of electrical properties within the composite and the associated manufacturing, damage, or strain conditions. With knowledge of the fiber layup, this MWM-Array technology is able to detect damage and strain/stress as a function of depth and fiber orientation. This work has been funded by NASA, NA V AIR and the Army for applications ranging from composite overwrapped pressure vessels (COPVs) to aircraft structures and rotorcraft blades. This presentation will specifically present background on the MWM-Array technology, results from the micromechanical modeling effort, and results from ongoing efforts for high resolution imaging and volumetric strain sensing.

Washabaugh, Andrew↗
NASA NTRS2012

Drilling, Coring and Sampling Using Piezoelectric Actuated Mechanisms: From the USDC to a Piezo-Rotary-Hammer Drill

NASA exploration missions are increasingly including sampling tasks but with the growth in engineering experience (particularly, Phoenix Scout and MSL) it is now very much recognized that planetary drilling poses many challenges. The difficulties grow significantly with the hardness of sampled material, the depth of drilling and the harshness of the environmental conditions. To address the requirements for samplers that could be operated at the conditions of the various bodies in the solar system, a number of piezoelectric actuated drills and corers were developed by the Advanced Technologies Group of JPL. The basic configuration that was conceived in 1998 is known as the Ultrasonic/Sonic Driller/Corer (USDC), and it operates as a percussive mechanism. This drill requires as low preload as 10N (important for operation at low gravity) allowing to operate with as low-mass device as 400g, use an average power as low as 2- 3W and drill rocks as hard as basalt. A key feature of this drilling mechanism is the use of a free-mass to convert the ultrasonic vibrations generated by piezoelectric stack to sonic impacts on the bit. Using the versatile capabilities f the USDC led to the development of many configurations and device sizes. Significant improvement of the penetration rate was achieved by augmenting the hammering action by rotation and use of a fluted bit to remove cuttings. To reach meters deep in ice a wireline drill was developed called the Ultrasonic/Sonic Gopher and it was demonstrated in 2005 to penetrate about 2-m deep at Antarctica. Jointly with Honeybee Robotics, this mechanism is currently being modified to incorporate rotation and inchworm operation forming Auto-Gopher to reach meters deep in rocks. To take advantage of the ability of piezoelectric actuators to operate over a wide temperatures range, piezoelectric actuated drills were developed and demonstrated to operate at as cold as -200oC and as hot as 500oC. In this paper, the developed mechanisms will be reviewed and discussed including the configurations, capabilities, and challenges.

ultrasonic/Sonic Driller/ Corer (USDC)↗
NASA NTRS2013

NDE Evidence for the Damage Arrestment Performance of PRSEUS Composite Cube During High-Pressure Load Test

As an approach to light-weight, cost-effective and manufacturable structures required to enable the hybrid wing body aircraft, The Boeing Company, Inc. and NASA have developed the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. A PRSEUS pressure cube was developed as a risk reduction test article to examine a new integral cap joint concept as part of a building block approach for technology development of the PRSEUS concept. The overall specimen strength exceeded the 18.4 psi load requirement as testing resulted in the cube reaching a final pressure load of around 48 psi prior to catastrophic failure. The cube pressure test verified that the joints and structure were capable of sustaining the required loads, and represented the first testing of joined PRSEUS structure. This paper will address the damage arrestment performance of the stitched PRSEUS structure. Following catastrophic failure of the cube, ultrasonic pulse-echo inspection found that the localized damage, surrounding a barely-visible impact damage site, did not change noticeably between just after impact and catastrophic failure of the cube, and did not play a role in the catastrophic failure event. Ultrasonic inspection of the remaining intact cube panels presented three basic types of indications: delaminations between laminae parallel to the face sheets, lying between face sheet and tear strap layers, or between tear strap and flange layers; delaminations above the noodles of stringers, frames or integral caps, lying within face sheet or tear strap layers; and delaminations between the laminae in the inner fillets of the integral caps, where pulloff stresses were expected to be highest. Delaminations of all three types were predominantly contained by the first row of stitches encountered. For the small fraction of delaminations extending beyond the first row of stitches, all were contained by the second stitch row.

Johnston, Patrick H.↗
NASA NTRS1993

Impact damage tolerance of thin wall composite struts

An experimental investigation was made to study the impact damage tolerance of thin wall composite struts made of both brittle epoxy and toughened epoxy based composite materials. Damage parameters such as barely visible surface damage and internal damage represented by the ultrasonic C-scan, and residual compressive strengths were evaluated against impact energy for two impactor sizes. From both a damage resistance (internal damage vs. impact energy) and a damage tolerance (residual compressive strength vs. internal damage) point of view, the toughened IM7/977-2 struts exhibited better performance than the brittle epoxy based T50/934 struts. This is attributed to the toughening mechanism in 977-2 which impedes delamination initiation from impact, and delamination growth and subsequent buckling under a compression loading. At barely visible damage thresholds, regardless of the impactor sizes, a maximum strength reduction of 45-55 percent was observed for the T50/934 struts, and approximately 10 percent for IM7/977-2 struts. This is of great interest for developing a damage tolerance design approach and risk assessment methodology in which the design allowable would be defined by the residual strength at the threshold of barely visible damage.

Chen, G.-S.↗
NASA NTRS1992

Acoustic emission monitoring of low velocity impact damage in graphite/epoxy laminates during tensile loading

An acoustic emission (AE) system was set up in a linear location data acquisition mode to monitor the tensile loading of eight-ply quasi-isotropic graphite/epoxy specimens containing low velocity impact damage. The impact damage was induced using an instrumented drop weight tower. During impact, specimens were supported by either an aluminum plate or a membrane configuration. Cross-sectional examinations revealed that the aluminum plate configuration resulted in primarily matrix cracking and back surface fiber failure. The membrane support resulted in only matrix cracking and delamination damage. Penetrant enhanced radiography and immersion ultrasonics were used in order to assess the amount of impact damage in each tensile specimen. During tensile loading, AE reliably detected and located the damage sites which included fiber failure. All specimens with areas of fiber breakage ultimately failed at the impact site. AE did not reliably locate damage which consisted of only delaminations and matrix cracking. Specimens with this type of damage did not ultimately fail at the impact site. In summary, AE demonstrated the ability to increase the reliability of structural proof tests; however, the successful use of this technique requires extensive baseline testing.

Parker, Bradford H.↗