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NASA NTRS1989

Fractography of composite delamination

Delamination is a major failure mode of carbon fiber organic matrix composites. It can occur under a variety of loading conditions. Efforts to develop predictive models of the delamination of carbon fiber composites are hampered by a lack of information about the micromechanics of impact damage and delamination growth. Crack formation and propagation in these materials cannot be observed in sufficient detail to determine micro-damage using currently available nondestructive methods such as acoustic backscattering or x ray imaging. Consequently, destructive methods are required. Delamination of composites in Mode I, Mode II and after low energy impact loads were investigated using metallographic techniques of potting the failed specimens, sectioning and examining the cut sections for damage modes.

Bascom, W. D.↗

NASA NTRSDate not supplied

Modeling of Response of Thermoplastic Composites Under High Energy Impact

This work investigates the response of thermoplastic composites under impact loading. Panels fabricated with the material system under consideration – carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK) – were subject to impact with an Aluminum projectile, at low and high velocities. At lower velocities, the projectile rebounded from the panel after impact and caused damage e.g. delaminations. Finite element models were developed to model this test using LS-DYNA®, with material model MAT299, a continuum damage model based on the LaRC04 criteria, to capture the dynamic response and damage modes in the T700/LMPAEK panels. Interlaminar delaminations were modeled using the cohesive contact formulation available within LS-DYNA. Previous work by the authors showed that delaminations were consistently underpredicted in size, relative to the test. It was surmised that this was due to effects of strain rate on intralaminar and interlaminar response of the T700/LMPAEK material system. Therefore, the current work is focused on incorporating strain rate effects in modeling the interlaminar response. Rate dependence was incorporated using ‘one-way tie-break contact’ in LS-DYNA, wherein, the Mode-II fracture toughness of the LMPAEK resin, G IIc , was assumed to be an exponential function of the strain rate. In particular, G IIc , was modeled to exponentially decrease at higher strain rates. Models with this form of rate dependence favorably correlated with experimental data regarding delamination extent and rebound velocity, relative to prior models without strain rate effects.

Composite Materials↗

NASA NTRS2006

A Damage Model for the Simulation of Delamination in Advanced Composites under Variable-Mode Loading

A thermodynamically consistent damage model is proposed for the simulation of progressive delamination in composite materials under variable-mode ratio. The model is formulated in the context of Damage Mechanics. A novel constitutive equation is developed to model the initiation and propagation of delamination. A delamination initiation criterion is proposed to assure that the formulation can account for changes in the loading mode in a thermodynamically consistent way. The formulation accounts for crack closure effects to avoid interfacial penetration of two adjacent layers after complete decohesion. The model is implemented in a finite element formulation, and the numerical predictions are compared with experimental results obtained in both composite test specimens and structural components.

Turon, A.↗

NASA NTRS1988

A cumulative damage model for continuous fiber composite laminates with matrix cracking and interply delaminations

The present cumulative damage model for the prediction of stiffness loss in graphite/epoxy laminates applies a thermomechanical constitutive theory for elastic composites with distributed damage. The model proceeds from a continuum mechanics and thermodynamics approach in which the distributed damage is characterized by a set of second-order tensor-valued internal state variables. A set of damage-dependent laminated plate equations is obtained; this is developed by modifying classical Kirchhoff plate theory.

Allen, David H.↗

NASA NTRSDate not supplied

Understanding Variability in Mechanical Behavior of Adhesively Bonded Sandwich Joints due to Stochastic Material Damage

A mesoscale progressive damage analysis was applied to the analysis of recently tested adhesively bonded sandwich panels, in which ten nominally identical tension loaded panels failed in three different failure modes, with peakloads ranging from 13.0 –16.1 kips. A parametric finite element model for progressive damage analysis of an adhesively bonded joint (ABJ) considering matrix and fiber damage, and delamination cracks in unidirectional and fabric composite sections of the joint, as well as core crushing, and adhesive fracture was developed. The model was developed using Abaqus/Explicit and utilized continuum damage mechanics material models for intralaminar damage in the facesheet and doubler plies, cohesive elements for delamination and adhesive debonding, and discretized cells considering plasticity to model crushing of the aluminum honeycomb core. Analysis predictions obtained with a pristine model agreed well with the average experimental peak load, strain in the joint, and post-test damage states. Then, various methods to incorporate stochastic material variability into ABJ model were evaluated. These methods included simulation of pre-existing matrix damage, pre-existing adhesive porosity, and uniform modification of adhesive properties. These material and manufacturing defects changed the damage mode predictions in some cases. The analysis of stochastic strength due to the considered defects revealed unintuitive damage mode interaction in the ABJ, explaining some structure-property relationships observed experimentally.

Richard Larson↗

NASA NTRS1979

Low-velocity impact damage in graphite-fiber reinforced epoxy laminates

An experimental investigation was conducted to identify the failure mechanisms and to understand damage propagation in compression-loaded composite structures. The tests were conducted on several laminates of different ply orientation with thickness that ranged from 0.56 to 0.75 cm. The panels were damaged by 1.27-cm-diameter aluminum spheres propelled normal to the specimen surface at velocities ranging from 30 m/s to 140 m/s. Results indicate that there is significant internal laminate damage due to low-velocity impact with no surface damage. The internal damage consists of delamination and intraply cracking. Three damage propagation modes were identified as causing specimen failure; which are delamination, axial load-lateral deformation coupling, and local shear failure.

Rhodes, M. D.↗

NASA NTRSDate not supplied

Permanent, Transparent Anti-Fog Coating for Spacesuit Helmet

Fogging of polycarbonate spacesuit helmets is detrimental to astronaut safety and to mission success. Currently used anti-fogging methods are temporary and require the reapplication of a coating before each use. These temporary solutions have been shown to delaminate during use and have led to eye irritation and temporary blindness during spacewalks. Potential permanent solutions NASA has previously tested lack in durability and are prone to coating damage and delamination during cleaning. Lynntech is leveraging its experience with coating development to fabricate an anti-fog coating with the durability necessary for permanent use, to be applied to polycarbonate. In this SBIR Phase I project, Lynntech has demonstrated the proof of concept by applying our coating to flat polycarbonate and characterized the durability of its anti-fogging properties. Toward this end, Lynntech has developed a breath simulating testbed, exposing coatings to conditions they would experience on the interior of a spacesuit helmet during use. Additionally, Lynntech is developing an application method to uniformly deposit their coating on non-planar objects, such as a prototype spacesuit helmet.

spacesuit↗

NASA NTRS2016

Fuselage Versus Subcomponent Panel Response Correlation Based on ABAQUS Explicit Progressive Damage Analysis Tools

Analysis performed in this study substantiates the need for high fidelity vehicle level progressive damage analyses (PDA) structural models for use in the verification and validation of proposed sub-scale structural models and to support required full-scale vehicle level testing. PDA results are presented that capture and correlate the responses of sub-scale 3-stringer and 7-stringer panel models and an idealized 8-ft diameter fuselage model, which provides a vehicle level environment for the 7-stringer sub-scale panel model. Two unique skin-stringer attachment assumptions are considered and correlated in the models analyzed: the TIE constraint interface versus the cohesive element (COH3D8) interface. Evaluating different interfaces allows for assessing a range of predicted damage modes, including delamination and crack propagation responses. Damage models considered in this study are the ABAQUS built-in Hashin procedure and the COmplete STress Reduction (COSTR) damage procedure implemented through a VUMAT user subroutine using the ABAQUS/Explicit code.

Gould, Kevin E.↗

NASA NTRS1985

Delamination and debonding of materials

The general topics consist of stress analysis, mechanical behavior, and fractography/NDI of composite laminates. Papers are presented on a dynamic hybrid finite-element analysis for interfacial cracks in composites, energy release rate during delamination crack growth in composite laminates, matrix deformation and fracture in graphite-reinforced epoxies, and the role of delamination and damage development on the strength of thick notched laminates. In addition, consideration is given to a new ply model for interlaminar stress analysis, a fracture mechanics approach for designing adhesively bonded joints, the analysis of local delaminations and their influence on composite laminate behavior, and moisture and temperature effects on the mixed-mode delamination fracture of unidirectional graphite/epoxy.

Johnson, W. S.↗

NASA NTRS1991

The fatigue behaviour of orthotropic laminates under tension-compression loading

The fatigue behavior of orthotropic laminates (0, +/-45, 0 deg)2s and (90, +/-45, 90 deg)2s, has been evaluated under alternating tension-compression loading. Even though the first laminate is much stronger than the second, both started to fail by delamination. Visual damage started to show only at the very end of the fatigue life but measurement of the stiffness showed that degradation starts at about 80 percent of the fatigue life. The first laminate failed in compression after delamination between the 0 and the 45 deg laminae, while the second failed in tension after delamination between the +45 and -45 deg laminae. It is shown that the interlaminar fatigue strength of both laminate structures can be correlated to the applied fatigue load.

Rotem, A.↗

NASA NTRS2016

A Biaxial-Bending Test to Observe the Growth of Interacting Delaminations in a Composite Laminate Plate

It is not easy to isolate the damage mechanisms associated with low-velocity impact in composites using traditional experiments. In this work, a new experiment is presented with the goal of generating data representative of progressive damage processes caused by low-velocity impact in composite materials. Carbon fiber reinforced polymer test specimens were indented quasi-statically such that a biaxial-bending state of deformation was achieved. As a result, a three-dimensional damage process, involving delamination and delamination-migration, was observed and documented using ultrasonic and x-ray computed tomography. Results from two different layups are presented in this paper. Delaminations occurred at up to three different interfaces and interacted with one another via transverse matrix cracks. Although this damage pattern is much less complex than that of low-velocity impact on a plate, it is more complex than that of a standard delamination coupon test and provides a way to generate delamination, matrix cracking, and delamination-migration in a controlled manner. By limiting the damage process in the experiment to three delaminations, the same damage mechanisms seen during impact could be observed but in a simplified manner. This type of data is useful in stages of model development and validation when the model is capable of simulating simple tests, but not yet capable of simulating more complex and realistic damage scenarios.

McElroy, Mark↗

NASA NTRS1969

Diffusion bond method of joining steel and a TFE-bronze composite

Diffusion bonding method does not affect the mechanical properties of steel nor the strength of Teflon. It alleviates problems of adhesive outgassing, radiation damage, and delamination.

Lalacona, F. P.↗

NASA NTRS1975

Flight service evaluation of Kevlar-49/epoxy composite panels in wide-bodied commercial transport aircraft

Kevlar-49 fairing panels were inspected and found to be performing satisfactorily after two years flight service on an Eastern and an Air Canada L-1011. Six panels are on each aircraft including sandwich and solid laminate wing-body panels, and 300 F service aft engine fairings. Some of the panels were removed from the aircraft to permit inspection of inner surfaces and fastener hole conditions. Minor defects such as surface cracks due to impact damage, small delaminated areas, elongation and fraying of fastener holes, were noted. None of these defects were considered serious enough to warrant corrective action in the opinion of airline personnel. The defects are typical for the most part of defects noted on similar fiberglass parts.

Stone, R. H.↗

NASA NTRS1988

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.↗

NASA NTRS1990

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

Martin, Roderick H.↗

NASA NTRS1992

Through-the Thickness(R) braided composites for aircraft applications

Material and structural specimens of Through-the-Thickness(R) braided textile composites were tested in a variety of experiments. The results have demonstrated that the preform architecture provides significant payoffs in damage tolerance, delamination resistance, and attachment strength. This paper describes the braiding process, surveys the experimental data base, and illustrates the application of three dimensional braiding in aircraft structures.

Brown, Richard T.↗

NASA NTRS1993

Effects of thermal and moisture cycling on the internal structure of stitched RTM laminates

Conventional aerospace composites are strong and stiff in the directions parallel to the carbon fibers, but they are prone to delaminations and damage in the through-the-thickness directions. Recent research has shown that substantial improvements in damage tolerance are obtained from textile composites with Z-direction reinforcement provided by stitching, weaving, or braiding. Because of the mismatch in thermal and moisture expansion properties of the various material components, there is a potential for microcracks to develop in the resin matrix. These cracks can form to relieve the mechanical stresses that are generated during curing or in-service temperature cycles.

Walker, Jeff↗

NASA NTRS2002

An Irreversible Constitutive Law for Modeling the Delamination Process Using Interface Elements

An irreversible constitutive law is postulated for the formulation of interface elements to predict initiation and progression of delamination in composite structures. An exponential function is used for the constitutive law such that it satisfies a multi-axial stress criterion for the onset of delamination, and satisfies a mixed mode fracture criterion for the progression of delamination. A damage parameter is included to prevent the restoration of the previous cohesive state between the interfacial surfaces. To demonstrate the irreversibility capability of the constitutive law, steady-state crack growth is simulated for quasi-static loading-unloading cycle of various fracture test specimens.

Goyal, Vinay K.↗