Search NASA⌕ Search

SEARCH · Search NASA

Results for “Composites Load Testing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 577 records · Page 32

Uniaxial and biaxial tensioning effects on thin membrane materials

Thin laminated membranes are being considered for various surface applications on future large space structural systems. Some of the thin membranes would be stretched across or between structural members with the requirement that the membrane be maintained within specified limits of smoothness which would be dictated by the particular applications such as antenna reflector requirements. The multiaxial tensile force required to maintain the smoothness in the membrane needs to be determined for use in the structure design. Therefore, several types of thicknesses of thin membrane materials have been subjected to varied levels of uniaxial and biaxial tensile loads. During the biaxial tests, deviations of the material surface smoothness were measured by a noncontacting capacitance probe. Basic materials consisted of composites of vacuum deposited aluminum on Mylar and Kapton ranging in thickness from 0.00025 in (0.000635 cm) to 0.002 in (0.00508 cm). Some of the material was reinforced with Kevlar and Nomex scrim. The uniaxial tests determined the material elongation and tensile forces up to ultimate conditions. Biaxial tests indicated that a relatively smooth material surface could be achieved with tensile force of approximately 1 to 15 Newtons per centimeter, depending upon the material thickness and/or reinforcement.

Hinson, W. F.↗

Fundamental aspects of polyimide dry film and composite lubrication: A review

The tribological properties of polyimide dry films and composites are reviewed. Friction coefficients, wear rates, transfer film characteristics, wear surface morphology, and possible wear mechanisms of several different polyimide films, polyimide-bonded solid lubricants, polyimide solid bodies, and polyimide composites are discussed. Such parameters as temperature, type of atmosphere, load, contact stress, and specimen configuration are investigated. Data from an accelerated test device (Pin-on-Disk) are compared to similar data obtained from an end use application test device (plain spherical bearing).

Fusaro, R. L.↗

Cyclic debonding of adhesively bonded composites

The fatigue behavior of a simple composite to composite bonded joint was analyzed. The cracked lap shear specimen subjected to constant amplitude cyclic loading was studied. Two specimen geometries were tested for each bonded system: (1) a strap adherend of 16 plies bonded to a lap adherend of 8 plies; and (2) a strap adherend of 8 plies bonded to a lap adherend of 16 plies. In all specimens the fatigue failure was in the form of cyclic debonding with some 0 deg fiber pull off from the strap adherend. The debond always grew in the region of adhesive that had the highest mode (peel) loading and that region was close to the adhesive strap interface.

Mall, S.↗

Characterization of Mode 1 and Mode 2 delamination growth and thresholds in graphite/peek composites

Composite materials often fail by delamination. The onset and growth of delamination in AS4/PEEK, a tough thermoplastic matrix composite, was characterized for mode 1 and mode 2 loadings, using the Double Cantilever Beam (DCB) and the End Notched Flexure (ENF) test specimens. Delamination growth per fatigue cycle, da/dN, was related to strain energy release rate, G, by means of a power law. However, the exponents of these power laws were too large for them to be adequately used as a life prediction tool. A small error in the estimated applied loads could lead to large errors in the delamination growth rates. Hence strain energy release rate thresholds, G sub th, below which no delamination would occur were also measured. Mode 1 and 2 threshold G values for no delamination growth were found by monitoring the number of cycles to delamination onset in the DCB and ENF specimens. The maximum applied G for which no delamination growth had occurred until at least 1,000,000 cycles was considered the threshold strain energy release rate. Comments are given on how testing effects, facial interference or delamination front damage, may invalidate the experimental determination of the constants in the expression.

Martin, Roderick H.↗

Characterization of Mode I and Mode II delamination growth and thresholds in AS4/PEEK composites

Composite materials often fail by delamination. The onset and growth of delamination in AS4/PEEK, a tough thermoplastic matrix composite, was characterized for mode 1 and mode 2 loadings, using the Double Cantilever Beam (DCB) and the End Notched Flexure (ENF) test specimens. Delamination growth per fatigue cycle, da/dN, was related to strain energy release rate, G, by means of a power law. However, the exponents of these power laws were too large for them to be adequately used as a life prediction tool. A small error in the estimated applied loads could lead to large errors in the delamination growth rates. Hence strain energy release rate thresholds, G sub th, below which no delamination would occur were also measured. Mode 1 and 2 threshold G values for no delamination growth were found by monitoring the number of cycles to delamination onset in the DCB and ENF specimens. The maximum applied G for which no delamination growth had occurred until at least 1,000,000 cycles was considered the threshold strain energy release rate. Comments are given on how testing effects, facial interference or delamination front damage, may invalidate the experimental determination of the constants in the expression.

Martin, Roderick H.↗

A curved beam test specimen for determining the interlaminar tensile strength of a laminated composite

A curved beam type of test specimen is evaluated for use in determining the through-the-thickness strength of laminated composites. Two variations of a curved beam specimen configuration (semi-circular and elliptical) were tested to failure using static and fatigue loads. The static failure load for the semi-circular specimens was found to be highly sensitive to flaw content, with the specimens falling into two distinct groups. This result supports the use of proof testing for structural validation. Static design allowables are derived based on the Weibull distribution. Fatigue data indicates no measured increase in specimen compliance prior to final fracture. All static and fatigue failures at room temperature dry conditions occurred catastrophically. The elliptical specimens demonstrated unusually high failure strengths indicating the presence of phenomena requiring further study. Results are also included for specimens exposed to a wet environment showing a matrix strength degradation due to moisture content. Further testing is under way to evaluate a fatigue methodology for matrix dominated failures based on residual static strength (wearout).

Hiel, Clement C.↗

A Comparison of Tension and Compression Creep in a Polymeric Composite and the Effects of Physical Aging on Creep Behavior

Experimental and analytical methods were used to investigate the similarities and differences of the effects of physical aging on creep compliance of IM7/K3B composite loaded in tension and compression. Two matrix dominated loading modes, shear and transverse, were investigated for two load cases, tension and compression. The tests, run over a range of sub-glass transition temperatures, provided material constants, material master curves and aging related parameters. Comparing results from the short-term data indicated that although trends in the data with respect to aging time and aging temperature are similar, differences exist due to load direction and mode. The analytical model used for predicting long-term behavior using short-term data as input worked equally as well for the tension or compression loaded cases. Comparison of the loading modes indicated that the predictive model provided more accurate long term predictions for the shear mode as compared to the transverse mode. Parametric studies showed the usefulness of the predictive model as a tool for investigating long-term performance and compliance acceleration due to temperature.

Gates, Thomas S.↗

Development and Calibration of a System-Integrated Rotorcraft Finite Element Model for Impact Scenarios

Two full-scale crash tests of an MD-500 helicopter were conducted in 2009 and 2010 at NASA Langley's Landing and Impact Research Facility in support of NASA s Subsonic Rotary Wing Crashworthiness Project. The first crash test was conducted to evaluate the performance of an externally mounted composite deployable energy absorber (DEA) under combined impact conditions. In the second crash test, the energy absorber was removed to establish baseline loads that are regarded as severe but survivable. The presence of this energy absorbing device reduced the peak impact acceleration levels by a factor of three. Accelerations and kinematic data collected from the crash tests were compared to a system-integrated finite element model of the test article developed in parallel with the test program. In preparation for the full-scale crash test, a series of sub-scale and MD-500 mass simulator tests were conducted to evaluate the impact performances of various components and subsystems, including new crush tubes and the DEA blocks. Parameters defined for the system-integrated finite element model were determined from these tests. Results from 19 accelerometers placed throughout the airframe were compared to finite element model responses. The model developed for the purposes of predicting acceleration responses from the first crash test was inadequate when evaluating more severe conditions seen in the second crash test. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used to calibrate model results for the full-scale crash test without the DEA. This combination of heuristic and quantitative methods identified modeling deficiencies, evaluated parameter importance, and proposed required model changes. The multidimensional calibration techniques presented here are particularly effective in identifying model adequacy. Acceleration results for the calibrated model were compared to test results and the original model results. There was a noticeable improvement in the pilot and copilot region, a slight improvement in the occupant model response, and an over-stiffening effect in the passenger region. One lesson learned was that this approach should be adopted early on, in combination with the building-block approaches that are customarily used, for model development and pretest predictions. Complete crash simulations with validated finite element models can be used to satisfy crash certification requirements, potentially reducing overall development costs.

Annett, Martin S.↗

Analytical Simulation of the Effects of Local Mechanisms on the Tensile Response of CMC Minicomposites

A micromechanics-based method based on a fiber shear lag analysis was developed to analyze the fast fracture response of uncoated ceramic matrix minicomposites under room temperature conditions. The model was applied to two SiCf/SiC minicomposite systems that were fabricated by Rolls-Royce and the University of Connecticut. The analysis approach does not require the assumption that matrix cracks propagate along the entire width of the minicomposite. The ratio of the fiber slip length to the crack spacing was found to be a key parameter driving the stress level at which the proportional limit takes place and the secondary modulus. Parametric studies were performed to investigate the effect of interfacial shear stress, fiber volume fraction and percentage of the composite that remains uncracked on the proportional limit stress and the composite secondary modulus. This work will allow increased understanding of the key material mechanisms that take place during the fast fracture loading and can be expanded to provide improved analysis methods for full macro composites. simulations to simulations of a flat panel impact test, have been performed to fully exercise and evaluate the capabilities of the developed model.

Micromechanics↗

Towards Erecting Straighter Lightweight Towers on the Moon Using Deployable Guy Wires

This paper reports our static stability test findings for a simple guy wire system to correct the natural lateral deflections of an 8.5m tall, compact deployable composite tower intended to support exploration of lunar permanently shadowed regions by nearby robotic assets. Deployable composite booms with microgravity flight heritage are currently being investigated at NASA Langley Research Center (LaRC) and Massachusetts Institute of Technology(MIT)’s Space Resources Workshop for their potential to be vertically deployed in the lunar gravity field, in support of NASA’s Artemis campaign. These applications include vertical solar arrays and the provision of elevated lines-of-sight to science or engineering payloads on landers and rovers, in support of nearby or distant crewed or robotic assets exploring scientifically interesting and hard to reach areas. Useful elevated payloads include radio repeaters, remote sensing and imaging, navigation and power beaming systems. However, while these lightweight booms have an excellent height to mass ratio, they typically exhibit slight axial curvature upon deployment resulting in appreciable lateral dead-load deflection of the tip mass relative to the tower base. This static deflection increases with tower height and tip mass, not only constraining the value delivered by the tower but also endangering its integrity. To develop a competitive, lightweight deployable composite boom tower, a capability to correct static deflections during and after deployment may be required. This paper presents a pathfinder deployable guy wire stability system for the MIT / LaRC self-erecting composite boom lunar tower that provides real time measurements, maintains tension passively, and can serve as a reconfigurable platform to test new guy wire components, configurations and control algorithms. Using a validated, calibrated photogrammetry system, the natural lateral deflection of the boom tip relative to the boom base at different deployed heights in Earth’s gravity field was recorded. With real-time tension measurements it was found that guy wires can significantly reduce the tip deflection of a deployable composite boom under dead load. Specifically, we found that (1) control capability is greatest where it is needed most, i.e. for the lever arm closest to being opposite the direction of deflection, and (2) for a tower height of at least 8.5 m and arm length of at least 60 cm, a solution of differential tension in all three arms exists and, in principle, provides sufficient control capability to correct or significantly reduce boom deflections. We also found that natural deflections occur almost entirely out-of-plane of the seams of the boom cross-section, which was expected, and that the natural boom tip lateral deflection under dead load upon deployment was ~5% of boom deployed length, unexpectedly exceeding the manufacturing acceptance specification of 1%.Ongoing and future collaborative work between LaRC and MIT includes the further investigation of the unexpected lateral deflection, testing of alternative guy wire system designs at higher tensions and higher deployed heights, as well as trade studies of costs and benefits of an optimized integrated guywire system compared to other types of static stability solutions.

lunar towers↗

Composite binder, processing, and particle size effects on mechanical properties of non-hazardous high explosive surrogates

Plastic-bonded explosives (PBX) are polymer matrix composites that are highly loaded with micron-scale explosive crystals. The thermal and mechanical properties of these materials must be well-understood so that appropriate engineering models can be developed, but testing such properties under many scenarios can be hazardous and expensive. A non-hazardous PBX surrogate (“mock”) may be used in place of a PBX in many experiments if the thermomechanical properties are well-matched. Our previous research has shown that 5-iodo-2'-deoxyuridine (IDOX) is a promising crystalline filler material for the explosive cyclotetramethylene-tetranitramine (HMX). In this study, we investigate how the binder composition, variations in the IDOX particle size distribution, and pressing temperature affect the compressive strength and elastic modulus. We observe that while the binder system used in the composite dominates the mechanical response, the particle size distribution and pressing conditions do have a measurable effect on the material compliance and strength.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Influence of plasticizers on thermal and mechanical properties of biocomposite filaments made from lignin and polylactic acid for 3D printing

Polylactic acid (PLA) and organosolv lignin were mixed at different ratios and extruded to obtain PLA-lignin composite filaments. PLA was replaced with lignin up to 20 wt%. Two plasticizers (polyethylene glycol (PEG) 2000 and struktol TR451) were added in varying concentrations to enhance the properties of PLA_L20 (20% lignin in PLA) composite filaments. Furthermore, the effect of lignin in PLA, and PEG, and struktol in PLA_L20 composites was investigated via tensile test, differential scanning calorimetry, thermogravimetric analysis, scanning electron microscopy, Fourier transform infrared spectroscopy of the filaments, and dynamic mechanical analysis of 3D printed samples. A 2 wt% PEG was able to enhance both tensile stress and elongation at maximum load of PLA_L20 composite by 19% and 35%, respectively, whereas struktol TR451 was able to improve elongation at maximum load by 24%.

3D printing↗

In situ high-temperature 3D imaging of the damage evolution in a SiC nuclear fuel cladding material

Silicon carbide (SiC)-based nuclear fission fuel rod cladding has been considered as one of the possible designs for accident tolerant fuels. It is in the form of a SiC fibre reinforced SiC matrix composite tube (SiC f -SiC m ) with monolithic SiC outer and/or inner coating layers. This study focuses on the deformation and fracture processes in this material using in situ X-ray micro-computed tomography (XCT) at room temperature (RT) and 1200 °C in an inert gas environment in a C-ring compression loading configuration. Prior to testing, local properties and residual stresses were characterised using nanoindentation and Raman spectroscopy since they can impact the mechanical behaviour of the material. The 3D strain distribution, crack formation and propagation processes including the toughening mechanisms (e.g., crack deflection, micro-cracking, crack bridging and bifurcation) are investigated in the coating and underlying composites at RT and 1200 °C. There is no particular sequence which toughening mechanism occurs first – this is very different from the conventional toughening theory in ceramic-matrix composites under uniaxial tension loading. Indeed, no evidence of fibre pull-out or fibre fracture was observed in this SiC f -SiC m nuclear cladding material in the current C-ring compression configuration. The correlation between local measurements and bulk mechanical behaviour are discussed.

3D imaging↗

Nondestructive monitoring damage in composites using scanning laser acoustic microscopy

Several Nicalon fiber reinforced LAS (lithium alumino-silicate) glass matrix composites were tested to study the relation between the residual strength and the different amounts of damage. The samples were fatigued by four-point cyclic loading at a 5 Hz rate at 500 C for a different number of cycles. 10 MHz scanning laser acoustic microscope (SLAM) images were taken to monitor damage on the samples. Our SLAM results indicate that there were defects already existing throughout the sample before fatigue, and the resultant damage pattern from fatigue could be related to the initial defect distribution in the sample. Finally, the fatigued samples were fractured and the residual strength data could not be explained by the cyclic fatigue alone. Rather, the damage patterns evident in the SLAM images were needed to explain the scatter in the data. The results show that SLAM is useful in nondestructively monitoring damage and estimating residual strength of fatigued ceramic composites.

Wey, A. C.↗

Testing and Life Prediction for Composite Rotor Hub Flexbeams

A summary of several studies of delamination in tapered composite laminates with internal ply-drops is presented. Initial studies used 2D FE models to calculate interlaminar stresses at the ply-ending locations in linear tapered laminates under tension loading. Strain energy release rates for delamination in these laminates indicated that delamination would likely start at the juncture of the tapered and thin regions and grow unstably in both directions. Tests of glass/epoxy and graphite/epoxy linear tapered laminates under axial tension delaminated as predicted. Nonlinear tapered specimens were cut from a full-size helicopter rotor hub and were tested under combined constant axial tension and cyclic transverse bending loading to simulate the loading experienced by a rotorhub flexbeam in flight. For all the tested specimens, delamination began at the tip of the outermost dropped ply group and grew first toward the tapered region. A 2D FE model was created that duplicated the test flexbeam layup, geometry, and loading. Surface strains calculated by the model agreed very closely with the measured surface strains in the specimens. The delamination patterns observed in the tests were simulated in the model by releasing pairs of MPCs along those interfaces. Strain energy release rates associated with the delamination growth were calculated for several configurations and using two different FE analysis codes. Calculations from the codes agreed very closely. The strain energy release rate results were used with material characterization data to predict fatigue delamination onset lives for nonlinear tapered flexbeams with two different ply-dropping schemes. The predicted curves agreed well with the test data for each case studied.

Murri, Gretchen B.↗

Bearing-bypass loading on bolted composite joints

The effects of simultaneous bearing and bypass loading on a graphite-epoxy (T300/5208) laminate were investigated. Onset damage and ultimate strengths were determined for each test case. A finite element stress analysis was conducted for each test case. The computed local stresses were used with appropriate failure criteria to analyze the observed failure modes and strengths. An unexpected interaction of the effect of the bypass and bearing loads was found for the onset of compression reacted bearing damage. The interaction was caused by a decrease in the bolt-hole contact arc and a corresponding increase in the severity of the bearing loads. The amount of bolt-hole contact had a significant effect on local stresses and, thus, on the calculated damage-onset and ultimate strengths. An offset-compression failure mode was identified for laminate failure under compression bearing-bypass loading.

Crews, J. H., Jr.↗

Interfacial shear behavior of sapphire-reinforced NiAl composites

The interfacial shear behavior in near-equiatomic NiAl reinforced by sapphire filaments has been examined at room temperature using a fiber pushout test technique. The load-displacement data indicate a large variability in the initial interface failure stress, although reverse push behavior indicates a comparatively constant interfacial sliding friction stress. The observed behavior suggests that the presence of asperities on the fiber surfaces and nonuniformities in fiber diameter require constrained plastic flow within the NiAl matrix in order for interfacial shear to occur. The location, shape, severity, and distribution of fiber asperities as well as the uniformity of fiber diameter are critical to the interfacial shear process.

Moose, C. A.↗