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NASA NTRS1988

Advanced composite materials for precision segmented reflectors

The objective in the NASA Precision Segmented Reflector (PSR) project is to develop new composite material concepts for highly stable and durable reflectors with precision surfaces. The project focuses on alternate material concepts such as the development of new low coefficient of thermal expansion resins as matrices for graphite fiber reinforced composites, quartz fiber reinforced epoxies, and graphite reinforced glass. Low residual stress fabrication methods will be developed. When coupon specimens of these new material concepts have demonstrated the required surface accuracies and resistance to thermal distortion and microcracking, reflector panels will be fabricated and tested in simulated space environments. An important part of the program is the analytical modeling of environmental stability of these new composite materials concepts through constitutive equation development, modeling of microdamage in the composite matrix, and prediction of long term stability (including viscoelasticity). These analyses include both closed form and finite element solutions at the micro and macro levels.

Stein, Bland A.↗

NASA NTRS1990

Simplified design procedures for fiber composite structural components/joints

Simplified step-by-step design procedures are summarized, which are suitable for the preliminary design of composite structural components such as panels (laminates) and composite built-up structures (box beams). Similar procedures are also summarized for the preliminary design of composite bolted and adhesively bonded joints. The summary is presented in terms of sample design cases complemented with typical results. Guidelines are provided which can be used in the design selection process of composite structural components/joints. Also, procedures to account for cyclic loads, hygrothermal effects and lamination residual stresses are included.

Murthy, P. L. N.↗

NASA NTRS1989

Fiber-matrix interface failures

Interface fractures of aluminum-graphite composites under transverse loading are expected to occur within the graphite fibers, but very near the interface. Residual stresses in aluminum, reinforced with the new high modulus pitch-based fibers, are much lower than would be expected based on simple elasticity calculations. The excess stress may be relaxed by shearing internal to the fibers or at the interface rather than by plastic flow of the matrix. The internal shearing also occurs during repeated thermal cycling of these composites; the fibers are repeatedly intruded, then extruded, during repeated temperature excursions.

Rabenberg, Lew↗

NASA NTRS1991

Electrical-Discharge Machining With Additional Axis

Proposed electrical-discharge-machining (EDM) apparatus uses moveable vertical wire as electrode. Wire positionable horizontally along one axis as it slides vertically past workpiece. Workpiece indexed in rotation about horizontal axis. Because of symmetry of parts, process used to make two such parts at a time by defining boundary between them. Advantages: cost of material reduced, imparts less residual stress to workpiece, and less time spent machining each part when parts produced in such symmetrical pairs.

Malinzak, Roger M.↗

NASA NTRS1990

Effects of cure temperature, electron radiation, and thermal cycling on P75/930 composites

Graphite/epoxy composites are candidates for future space structures due to high stiffness and dimensional stability requirements of these structures. Typical graphite/epoxy composites are brittle and have high residual stresses which often result in microcracking during the thermal cycling typical of the space environment. Composite materials used in geosynchronous orbit applications will also be exposed to high levels of radiation. The purpose of the present study was to determine the effects of cure temperature and radiation exposure on the shear strength and thermal cycling-induced microcrack density of a high modulus, 275 F cure epoxy, P75/930. The results from the P75/930 are compared to previously reported data on P75/934 and T300/934 where 934 is a standard 350 F cure epoxy. The results of this study reveal that P75/930 is significantly degraded by total doses of electron radiation greater than 10(exp 8) rads and by thermally cycling between -250 F and 150 F. The P75/930 did not have improved microcrack resistance over the P75/934, and the 930 resin system appears to be more sensitive to electron radiation-induced degradation than the 934 resin system.

Funk, Joan G.↗

NASA NTRS1990

METCAN simulation of candidate metal matrix composites for high temperature applications

The METCAN (Metal Matrix Composite Analyzer) computer code is used to simulate the nonlinear behavior of select metal matrix composites in order to assess their potential for high temperature structural applications. Material properties for seven composites are generated at a fiber volume ratio of 0.33 for two bonding conditions (a perfect bond and a weak interphase case) at various temperatures. A comparison of the two bonding conditions studied shows a general reduction in value of all properties (except CTE) for the weak interphase case from the perfect bond case. However, in the weak interphase case, the residual stresses that develop are considerably less than those that form in the perfect bond case. Results of the computational simulation indicate that among the metal matrix composites examined, SiC/NiAl is the best candidate for high temperature applications at the given fiber volume ratio.

Lee, Ho-Jun↗

NASA NTRS1991

Computational simulation of hot composites structures

Three different computer codes developed in-house are described for application to hot composite structures. These codes include capabilities for: (1) laminate behavior (METCAN); (2) thermal/structural analysis of hot structures made from high temperature metal matrix composites (HITCAN); and (3) laminate tailoring (MMLT). Results for select sample cases are described to demonstrate the versatility as well as the application of these codes to specific situations. The sample case results show that METCAN can be used to simulate cyclic life in high temperature metal matrix composites; HITCAN can be used to evaluate the structural performance of curved panels as well as respective sensitivities of various nonlinearities, and MMLT can be used to tailor the fabrication process in order to reduce residual stresses in the matrix upon cool-down.

Chamis, Christos C.↗

NASA NTRS1991

Mechanical behavior of fiber reinforced SiC/RBSN ceramic matrix composites: Theory and experiment

The mechanical behavior of continuous fiber reinforced SiC/RBSN (Reaction Bonded Silicon Nitride) composites with various fiber contents is evaluated. Both catastrophic and noncatastrophic failures are observed in tensile specimens. Damage and failure mechanisms are identified via in-situ monitoring using NDE (nondestructive evaluation) techniques through the loading history. Effects of fiber/matrix interface debonding (splitting) parallel to fibers are discussed. Statistical failure behavior of fibers is also observed, especially when the interface is weak. Micromechanical models incorporating residual stresses to calculate the critical matrix cracking strength, ultimate strength, and work of pull-out are reviewed and used to predict composite response. For selected test problems, experimental measurements are compared to analytical predictions.

Chulya, Abhisak↗

NASA NTRS1991

Computational simulation of acoustic fatigue for hot composite structures

Predictive methods/computer codes for the computational simulation of acoustic fatigue resistance of hot composite structures subjected to acoustic excitation emanating from an adjacent vibrating component are discussed. Select codes developed over the past two decades at the NASA Lewis Research Center are used. The codes include computation of acoustic noise generated from a vibrating component, degradation in material properties of a composite laminate at use temperature, dynamic response of acoustically excited hot multilayered composite structure, degradation in the first ply strength of the excited structure due to acoustic loading, and acoustic fatigue resistance of the excited structure, including the propulsion environment. Effects of the laminate lay-up and environment on the acoustic fatigue life are evaluated. The results show that, by keeping the angled plies on the outer surface of the laminate, a substantial increase in the acoustic fatigue life is obtained. The effect of environment (temperature and moisture) is to relieve the residual stresses leading to an increase in the acoustic fatigue life of the excited panel.

Singhal, Surendra N.↗

NASA NTRS1991

Effects of water on the strength of Zerodur

An experimental design matrix was constructed to determine the effects of time and temperature water soak on the strength of Zerodur glass-ceramic. It was found that strength does increase in a nonlinear manner which is consistent with existing theories of crack tip blunting and residual stress reduction.

Tucker, Dennis S.↗

NASA NTRS1989

Effect of grinding on the fatigue life of titanium alloy (5 Al-2.5 Sn) under dry and wet conditions

The principal factors in the performance of aerospace materials are strength-to-weight ratio, fatigue life, fracture toughness, survivability and, of course, reliability. Machining processes and, in particular, grinding under adverse conditions have been found to cause damage to surface integrity and affect the residual stress distribution in the surface and subsurface region. These effects have a direct bearing on the fatigue life. In this investigation the effects of grinding conditions on the fatigue life of Titanium 5 Al-2.5Sn were studied. This alloy is used in ground form in the manufacturing of some critical components in the space shuttle's main engine. It is essential that materials for such applications be properly characterized for use in severe service conditions. Flat sub-size specimens 0.1 inch thick were ground on a surface grinding machine equipped with a variable speed motor at speeds of 2000 to 6000 rpm using SiC wheels of grit sizes 60 and 120. The grinding parameters used in this investigation were chosen from a separate study. The ground specimens were then fatigued at a selected stress and the resulting lives were compared with that of the virgin material. The surfaces of the specimens were examined under a scanning electron microscope, and the roughness and hardness were measured using a standard profilometer and microhardness tester, respectively. The fatigue life of the ground specimens was found to decrease with the increase in speed for both dry and wet conditions. The fatigue life of specimens ground under wet conditions showed a significant increase at the wheel speed of 2000 rpm for both the grit sizes and thereafter decreased with increase profilometry, microhardness measurements and scanning electron microscopic examination.

Rangaswamy, Partha↗

NASA NTRS1991

Interphase layer optimization for metal matrix composites with fabrication considerations

A methodology is presented to reduce the final matrix microstresses for metal matrix composites by concurrently optimizing the interphase characteristics and fabrication process. Application cases include interphase tailoring with and without fabrication considerations for two material systems, graphite/copper and silicon carbide/titanium. Results indicate that concurrent interphase/fabrication optimization produces significant reductions in the matrix residual stresses and strong coupling between interphase and fabrication tailoring. The interphase coefficient of thermal expansion and the fabrication consolidation pressure are the most important design parameters and must be concurrently optimized to further reduce the microstresses to more desirable magnitudes.

Morel, M.↗

NASA NTRS1990

Temperature-dependent tensile and shear response of P100/6061 graphite-aluminum

This paper summarizes the results of an investigation conducted to characterize tensile and shear response of P100/6061 graphite-aluminum composite in the temperature range -101 to 260 C. The off-axis tension test and Iosipescu shear test methods were employed to meet this objective. The experimental results indicate that both the fiber-dominated and matrix-dominated elastic properties exhibit relatively small changes in the considered temperature range. The effect of temperature on yielding and strength, however, is significant under longitudinal and shear loading. Residual stresses play a significant role in controlling the variation of the yield stress with temperature. The observed low transverse strength of the composite is explained by interfacial defects between adjacent precursor wires induced during fabrication.

Fujita, Takahiro↗

NASA NTRS1991

Computational simulation of acoustic fatigue for hot composite structures

This paper presents predictive methods/codes for computational simulation of acoustic fatigue resistance of hot composite structures subjected to acoustic excitation emanating from an adjacent vibrating component. Select codes developed over the past two decades at the NASA Lewis Research Center are used. The codes include computation of (1) acoustic noise generated from a vibrating component, (2) degradation in material properties of the composite laminate at use temperature, (3) dynamic response of acoustically excited hot multilayered composite structure, (4) degradation in the first-ply strength of the excited structure due to acoustic loading, and (5) acoustic fatigue resistance of the excited structure, including propulsion environment. Effects of the laminate lay-up and environment on the acoustic fatigue life are evaluated. The results show that, by keeping the angled plies on the outer surface of the laminate, a substantial increase in the acoustic fatigue life is obtained. The effect of environment (temperature and moisure) is to relieve the residual stresses leading to an increase in the acoustic fatigue life of the excited panel.

Singhal, S. N.↗

NASA NTRS1991

Effect of grinding conditions on the fatigue life of titanium 5Al-2.5Sn alloy

An investigation into the effect of grinding conditions on the fatigue life of titanium 5Al-2.5Sn is presented. Damage to surface integrity and changes in the residual stresses distribution are studied to assess changes in fatigue life. A surface grinding machine, operating at speeds ranging from 2000 to 6000 fpm and using SiC wheels of grit sizes 60 and 120, was used to grind flat subsize specimens of 0.1-in. thickness. After grinding, the specimens were fatigued at a chosen stress and compared with the unadulterated material. A standard profilometer, a microhardness tester, and a scanning electron microscope were utilized to examine surface characteristics and measure roughness and hardness. Increased grinding speed in both wet and dry applications tended to decrease the fatigue life of the specimens. Fatigue life increased markedly at 2000 fpm under wet conditions, but then decreased at higher speeds. Grit size had no effect on the fatigue life.

Rangaswamy, P.↗

NASA NTRS1990

On the application of large-eddy simulation to transitional wall-bounded flows

Large-eddy simulations of transition on a flat-plate boundary layer have been carried out. Standard residual stress models of the Smagorinsky type are excessively dissipative, but rescaling the model constant improves the prediction of the total (integrated) subgrid scale dissipation, leading to results that compare favorably with those of a direct simulation, at a small fraction of the computational effort.

Piomelli, Ugo↗

NASA NTRS1990

Wave propagation in composite media and material characterization

Characteristics of wave propagation in an undamaged composite medium are influenced by many factors, the most important of which are: microstructure, constituent properties, interfaces, residual stress fields, and ply lay-ups. Measurements of wave velocities, attenuation, and dispersion provide a powerful tool for nondestructive evaluation of these properties. Recent developments are reviewed for modeling ultrasonic wave propagation in fiber and particle-reinforced composite media. Additionally, some modeling studies are reviewed for the effects of interfaces and layering on attenuation and dispersion. These studies indicate possible ways of characterizing material properties by ultrasonic means.

Datta, Subhendu K.↗

NASA NTRS1992

Tailored metal matrix composites for high-temperature performance

A multi-objective tailoring methodology is presented to maximize stiffness and load carrying capacity of a metal matrix cross-ply laminated at elevated temperatures. The fabrication process and fiber volume ratio are used as the design variables. A unique feature is the concurrent effects from fabrication, residual stresses, material nonlinearity, and thermo-mechanical loading on the laminate properties at the post-fabrication phase. For a (0/90)(sub s) graphite/copper laminate, strong coupling was observed between the fabrication process, laminate characteristics, and thermo-mechanical loading. The multi-objective tailoring was found to be more effective than single objective tailoring. Results indicate the potential to increase laminate stiffness and load carrying capacity by controlling the critical parameters of the fabrication process and the laminate.

Morel, M. R.↗