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NASA NTRS1992

Fundamental concepts in the suppression of delamination buckling by stitching

Elementary results are presented for the buckling of stitched, laminated composites containing delamination cracks. The stitching fibers are assumed to provide continuous, linear restoring tractions opposing the deflection of the delaminated layer adjacent to the crack. It is shown that there exists a characteristic length a(0) for buckling: if the length, 2a, of the delamination crack exceeds 2a(0), then, when buckling occurs, it will consist of waves of period 2a(0) and will usually not span the whole delamination. Simple expressions are derived for the critical buckling load and the minimum stitching density required to suppress buckling of the delaminated layer.

Cox, B. N.↗

NASA NTRS2001

Effect of Stitching on Debonding in Composite Structural Elements

Stitched multiaxial warp knit materials have been suggested as viable alternatives to laminated prepreg materials for large aircraft structures such as wing skins. Analyses have been developed to quantify the effectiveness of stitching for reducing strain energy release rates in skin-stiffener debond, lap joint and sandwich debond configurations. Strain energy release rates were computed using the virtual crack closure technique. In all configurations, the stitches were shown to significantly reduce the strain energy release rate.

Raju, I. S.↗

NASA NTRS2008

Structural Efficiency of Stitched Rod-Stiffened Composite Panels with Stiffener Crippling

The structural efficiency of rod-stiffened stitched specimens is evaluated to determine their weight saving potential if the stiffeners were allowed to buckle at less than or equal to design ultimate load. Analytical and experimental results from rod-stiffened and blade-stiffened single-stiffener specimens are presented. In both cases, skin and flanges were stitched together through-the-thickness prior to curing. No mechanical fasteners were used for the assembly. Specimens were loaded to failure in axial compression. Failure modes are discussed. Finite element and experimental results agree for the response of the structures. For some specimen configurations, improved structural efficiency can be obtained by allowing stiffeners to buckle at design limit load rather than requiring that buckling not occur prior to design ultimate load. In addition, through-the-thickness stitching can change the failure mechanism by suppressing delamination between skin and flange. A parametric study is presented herein which describes the possible weight savings with this approach.

Jegley, Dawn C.↗

NASA NTRS2014

The Use of the STAGS Finite Element Code in Stitched Structures Development

In the last 30 years NASA has worked in collaboration with industry to develop enabling technologies needed to make aircraft more fuel-efficient and more affordable. The focus on the airframe has been to reduce weight, improve damage tolerance and better understand structural behavior under realistic flight and ground loading conditions. Stitched structure is a technology that can address the weight savings, cost reduction, and damage tolerance goals, but only if it is supported by accurate analytical techniques. Development of stitched technology began in the 1990's as a partnership between NASA and Boeing (McDonnell Douglas at the time) under the Advanced Composites Technology Program and has continued under various titles and programs and into the Environmentally Responsible Aviation Project today. These programs contained development efforts involving manufacturing development, design, detailed analysis, and testing. Each phase of development, from coupons to large aircraft components was supported by detailed analysis to prove that the behavior of these structures was well-understood and predictable. The Structural Analysis of General Shells (STAGS) computer code was a critical tool used in the development of many stitched structures. As a key developer of STAGS, Charles Rankin's contribution to the programs was quite significant. Key features of STAGS used in these analyses and discussed in this paper include its accurate nonlinear and post-buckling capabilities, its ability to predict damage growth, and the use of Lagrange constraints and follower forces.

Jegley, Dawn C.↗

NASA NTRS2015

Development of Stitched Composite Structure for Advanced Aircraft

NASA has created the Environmentally Responsible Aviation Project to develop technologies which will reduce the impact of aviation on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe that will enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company are working together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composites. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together and designed to maintain residual load-carrying capabilities under a variety of damage scenarios. With the PRSEUS concept, through-the-thickness stitches are applied through dry fabric prior to resin infusion, and replace fasteners throughout each integral panel. Through-the-thickness reinforcement at discontinuities, such as along flange edges, has been shown to suppress delamination and turn cracks, which expands the design space and leads to lighter designs. The pultruded rod provides stiffening away from the more vulnerable skin surface and improves bending stiffness. A series of building blocks were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. These building blocks addressed tension, compression, and pressure loading conditions. The emphasis of the development work has been to assess the loading capability, damage arrestment features, repairability, post-buckling behavior, and response of PRSEUS flat panels to out-of plane pressure loading. The results of this building-block program from coupons through an 80%-scale pressure box have demonstrated the viability of a PRSEUS center body for the Hybrid Wing Body (HWB) transport aircraft. This development program shows that the PRSEUS benefits are also applicable to traditional tube-andwing aircraft, those of advanced configurations, and other structures where weight and through-the-thickness strength are design considerations. An overview of the development of PRSEUS technology for commercial transport aircraft is the subject of this paper.

Jegley, Dawn↗

NASA NTRS2016

The Behavior of a Stitched Composite Large-Scale Multi-Bay Pressure Box

NASA has created the Environmentally Responsible Aviation (ERA) Project to develop technologies to reduce impact of aviation on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe to enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company have worked together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composite structures. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together and designed to maintain residual load-carrying capabilities under a variety of damage scenarios. With the PRSEUS concept, through-the-thickness stitches are applied through dry fabric prior to resin infusion, and replace fasteners throughout each integral panel. Through-the-thickness reinforcement at discontinuities, such as along flange edges, has been shown to suppress delamination and turn cracks, which expands the design space and leads to lighter designs. The pultruded rod provides stiffening away from the more vulnerable skin surface and improves bending stiffness. A series of building block tests were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. The final step in the building block series of tests is an 80%-scale pressure box representing a portion of the center section of a Hybrid Wing Body (HWB) transport aircraft. The testing of this test article under maneuver and internal pressure loading conditions is the subject of this paper. The experimental evaluation of this article, along with the other building block tests and the accompanying analyses, has demonstrated the viability of a PRSEUS center body for the HWB vehicle. Additionally, much of the development effort is also applicable to traditional tube-and-wing aircraft, advanced aircraft configurations, and other structures where weight and through-the-thickness strength are design considerations.

Jegley, Dawn C.↗

NASA NTRS2016

Ultrasonic Nondestructive Evaluation of Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) During Large-Scale Load Testing and Rod Push-Out Testing

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is a structural concept developed by the Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body (HWB) aircraft configuration. The HWB has long been a focus of NASA's environmentally responsible aviation (ERA) project, following a building block approach to structures development, culminating with the testing of a nearly full-scale multi-bay box (MBB), representing a segment of the pressurized, non-circular fuselage portion of the HWB. PRSEUS is an integral structural concept wherein skins, frames, stringers and tear straps made of variable number of layers of dry warp-knit carbon-fiber stacks are stitched together, then resin-infused and cured in an out-of-autoclave process. The PRSEUS concept has the potential for reducing the weight and cost and increasing the structural efficiency of transport aircraft structures. A key feature of PRSEUS is the damage-arresting nature of the stitches, which enables the use of fail-safe design principles. During the load testing of the MBB, ultrasonic nondestructive evaluation (NDE) was used to monitor several sites of intentional barely-visible impact damage (BVID) as well as to survey the areas surrounding the failure cracks after final loading to catastrophic failure. The damage-arresting ability of PRSEUS was confirmed by the results of NDE. In parallel with the large-scale structural testing of the MBB, mechanical tests were conducted of the PRSEUS rod-to-overwrap bonds, as measured by pushing the rod axially from a short length of stringer.

Johnston, Patrick H.↗

NASA NTRS2016

Acoustic Emission of Large PRSEUS Structures (Pultruded Rod Stitched Efficient Unitized Structure)

In the role of structural health monitoring (SHM), Acoustic Emission (AE) analysis is being investigated as an effective method for tracking damage development in large composite structures under load. Structures made using Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) for damage tolerant, light, and economical airframe construction are being pursued by The Boeing Company and NASA under the Environmentally Responsible Aircraft initiative (ERA). The failure tests of two PRSEUS substructures based on the Boeing Hybrid Wing Body fuselage concept were conducted during third quarter 2011 and second quarter 2015. One fundamental concern of these tests was determining the effectiveness of the stitched integral stiffeners to inhibit damage progression. By design, severe degradation of load carrying capability should not occur prior to Design Ultimate Load (DUL). While minor damage prior to DUL was anticipated, the integral stitching should not fail since this would allow a stiffener-skin delamination to progress rapidly and alter the transfer of load into the stiffeners. In addition, the stiffeners should not fracture because they are fundamental to structural integrity. Getting the best information from each AE sensor is a primary consideration because a sparse network of sensors is implemented. Sensitivity to stiffener-contiguous degradation is supported by sensors near the stiffeners, which increases the coverage per sensor via AE waveguide actions. Some sensors are located near potentially critical areas or "critical zones" as identified by numerical analyses. The approach is compared with the damage progression monitored by other techniques (e.g. ultrasonic C-scan).

Horne, Michael R.↗

NASA NTRSDate not supplied

History of Structural Stitching Development for Aerospace Applications

Layered composite structures are a commonly used, lightweight option for aerospace vehicles today. However, these structures are prone to delamination between plies as well as separation between co-cured sections such as skins and flanges. In addition, delamination can easily be induced by impact damage from events such as tool drops and hailstones. Since such delaminations are often not visible from the external surface of the structure, additional material or fasteners must be included in the design to ensure the structure will maintain the required load-carrying ability through its lifetime. However, adding extra material increases weight and reduces structural efficiency and adding fasteners and their associated holes reduces manufacturing efficiency and adds the requirement to inspect the holes since they could become crack initiation points. Alternate means to reduce delaminations could be beneficial. An alternative to these options is to build the structure with through-thickness reinforcement, such as using stitching threads, to limit delamination, increase out-of-plane strength, and provide a method to join structural elements together without fasteners. The history of through-thickness stitching as it could be applied to aerospace vehicles is described in this paper.

carbon-epoxy↗

DOE OSTI2025

Backbone Stitching in Bottlebrush Copolymer Mesodomains and the Impact of Side Chain Crystallization

We synthesized bottlebrush statistical copolymers (BSCPs) having poly(ethylene oxide) (PEO) and poly(dimethylsiloxane) (PDMS) side chains attached to a polynorbornene backbone. Small-angle X-ray scattering analysis showed that for densely grafted BSCPs, the scattering length density gradually transitions between the PEO and PDMS domains. For loosely grafted BSCPs, the polymer backbone formed a distinct mesodomain, with a lower electron and mass density than both the PEO and PDMS domains. The bottlebrush backbone essentially “stitches” the PEO and PDMS side chains, looping back and forth from the PEO to PDMS domains with the backbone segments oriented normal to the domain interfaces. Self-consistent field theory (SCFT) calculations validated the stitching of the backbone driven by the microphase separation of PEO and PDMS, along with a strong segmental order of the side chains in the melt. The reduced birefringence upon PEO crystallization suggests the disruption of the strong segmental order by the crystallization. Both the static intrinsic and the form birefringences of the BSCPs decreased upon PEO crystallization. Solid-state NMR confirmed the rigidity of PEO crystallites and the bottlebrush backbone. Self-assembly of BSCPs containing polyhedral oligomeric silsesquioxane (POSS) pendent groups was also evaluated by X-ray scattering, showing the formation of lamellar microdomains that inhibited POSS crystallization.

Hu, Mingqiu↗

NASA NTRS1985

Silicone-Rubber Stitching Seal

Fabric products protected from raveling by coating threads and filling stitching holes with silicone rubber. Uncored silicone rubber applied to stitching lines with air-pressurized sealant gun. Next, plastic release film placed on coated side, and blanket flipped over so release film lies underneath. Blanket then bagged and adhesive cured under partial vacuum of about 3.5 psi or under pressure. Applications include balloons, parachutes, ultralight aircraft, sails, rescue harnesses, tents, or other fabric products highly stressed in use.

Wang, D. S.↗

NASA NTRS1991

Micromechanics of fatigue in woven and stitched composites

The goal is to determine how microstructural factors, especially the architecture of microstructural factors, control fatigue damage in 3D reinforced polymer composites. Test materials were fabricated from various preforms, including stitched quasi-isotropic laminates, and through-the-thickness angle interlock, layer-to-layer angle interlock, and through-the-thickness stitching effect weaves. Preforms were impregnated with a tough resin by a special vacuum infiltration method. Most tests are being performed in uniaxial compression/compression loading. In all cases to date, failure has occurred not by delamination, but by shear failure, which occurs suddenly rather than by gradual macroscopic crack growth. Some theoretical aspects of bridging are also examined.

Cox, B. N.↗

NASA NTRS1993

The combined effect of glass buffer strips and stitching on the damage tolerance of composites

Recent research has demonstrated that through-the-thickness stitching provides major improvements in the damage tolerance of composite laminates loaded in compression. However, the brittle nature of polymer matrix composites makes them susceptible to damage propagation, requiring special material applications and designs to limit damage growth. Glass buffer strips, embedded within laminates, have shown the potential for improving the damage tolerance of unstitched composite laminates loaded in tension. The glass buffer strips, less stiff than the surrounding carbon fibers, arrest crack growth in composites under tensile loads. The present study investigates the damage tolerance characteristics of laminates that contain both stitching and glass buffer strips.

Kullerd, Susan M.↗

NASA NTRS2002

Structural Efficiency of Stitched Composite Panels with Stiffener Crippling

The structural efficiency of blade-stiffened stitched specimens is compared to determine their weight saving potential if blades were allowed to buckle at less than or equal to design ultimate load. Analytical and experimental results from four configurations of crippling specimens are presented. Specimen skin and blades were held together with through-the-thickness stitches prior to curing. No mechanical fasteners were used for the assembly. Tests were conducted with and without low-speed impact damage. Failure modes are discussed. Finite element and experimental results agree for the response of the structures. For some specimen configurations, improved structural efficiency can be obtained by allowing stiffeners to buckle at design limit load rather than requiring that buckling not occur prior to design ultimate load. A parametric study is presented herein which describes the possible weight savings with this approach.

Jegley, Dawn C.↗

NASA NTRS2000

Three-Dimensional Effects in the Plate Element Analysis of Stitched Textile Composites

Three-dimensional effects related to the analysis of stitched textile composites are discussed. The method of calculation is based on the virtual crack closure technique (VCCT), and models that model the upper and lower surface of the delamination or debond with two-dimensional (2D) plate elements rather than three-dimensional (3D) solid elements. The major advantages of the plate element modeling technique are a smaller model size and simpler geometric modeling. Details of the modeling of the laminated plate and the stitching are discussed.

Glaessgen, E. H.↗

NASA NTRS1997

Application of Laser Based Ultrasound for NDE of Damage in Thick Stitched Composites

As design engineers implement new composite systems such as thick, load bearing composite structures, they must have certifiable confidence in structure s durability and worthiness. This confidence builds from understanding the structural response and failure characteristics of simple components loaded in testing machines to tests on full scale sections. Nondestructive evaluation is an important element which can provide quantitative information on the damage initiation, propagation, and final failure modes for the composite structural components. Although ultrasound is generally accepted as a test method, the use of conventional ultrasound for in-situ monitoring of damage during tests of large structures is not practical. The use of lasers to both generate and detect ultrasound extends the application of ultrasound to in- situ sensing of damage in a deformed structure remotely and in a non-contact manner. The goal of the present research is to utilize this technology to monitor damage progression during testing. The present paper describes the application of laser based ultrasound to quantify damage in thick stitched composite structural elements to demonstrate the method. This method involves using a Q-switched laser to generate a rapid, local linear thermal strain on the surface of the structure. This local strain causes the generation of ultrasonic waves into the material. A second laser used with a Fabry-Perot interferometer detects the surface deflections. The use of fiber optics provides for eye safety and a convenient method of delivering the laser over long distances to the specimens. The material for these structural elements is composed of several stacks of composite material assembled together by stitching through the laminate thickness that ranging from 0.5 to 0.8 inches. The specimens used for these nondestructive evaluation studies had either impact damage or skin/stiffener interlaminar failure. Although little or no visible surface damage existed, internal damage was detected by laser based ultrasound.

Anastasi, Robert F.↗

NASA NTRS2005

Evaluation of a Compression-Loaded-Stitched-Multi-Bay Fuselage Panel With Barely Visible Impact Damage

The experimental results from a stitched VaRTM carbon-epoxy composite panel tested under uni-axial compression loading are presented along with nonlinear finite element analysis prediction of the response. The curved panel is divided by frames and stringers into six bays with a column of three bays along the compressive loading direction. The frames are supported at the frame ends to resist out-of-plane translation. Back-to-back strain gages are used to record the strain and displacement transducers were used to record the out-of-plane displacements. In addition a full-field-displacement measurement technique that utilizes a camera-based-stereo-vision system was used to record the displacements. The panel was loaded to 1.5 times the predicted initial buckling load (1st bay buckling load, P(sub er) from the nonlinear finite element analysis and then was removed from the test machine for impact testing. After impacting with 20 ft-lbs of energy using a spherical impactor to produce barely visible damage the panel was loaded in compression until failure. The buckling load of the first bay to buckle was 97% of the buckling load before impact. The stitching constrained the impact damage from growing during the loading to failure. Impact damage had very little overall effect on panel stiffness. Panel stiffness measured by the full-field-displacement technique indicated a 13% loss in stiffness after impact. The panel failed at 1.64 times the first panel buckling load. The barely visible impact damage did not grow noticeably as the panel failed by global instability due to stringer-web terminations at the frame locations. The predictions from the nonlinear analysis of the finite element modeling of the entire specimen were very effective in the capture of the initial buckling and global behavior of the panel. In addition, the prediction highlighted the weakness of the panel under compression due to stringer web terminations. Both the test results and the nonlinear predictions serve to reinforce the severe penalty in structural integrity caused by the low cost manufacturing technique to terminate the stringer webs, and demonstrates the importance of this type of sub-component testing and high fidelity failure analysis in the design of a composite fuselage.

Baker, Donald J.↗

NASA NTRS2005

Sub-pixel Spatial Resolution Micro-roughness Measurements with Interlaced Stitching

In this paper we describe a method to increase the spatial resolution of surface micro-roughness measurements. As the surface specifications for precision optics become more demanding, the metrology instruments must cover a broad spatial frequency range. Generally, multiple instruments are used to cover the full range of the specifications. For example, a Fizeau interferometer would be used to test low spatial frequency surface errors, a white light interferometer would be used for mid spatial frequency errors, and an AFM would be used for high spatial frequency errors. For some precision optics, three instruments would be necessary. However, in many applications, an increase in the spatial resolution of a metrology instrument could negate the need for multiple instruments. A solution to increase the spatial resolution of micro-roughness measurements obtained using white light interferometry with "interlaced stitching" will be presented. In "interlaced stitching", multiple interferometric measurements are made as the optic under test (or the CCD array) is laterally shifted at sub-pixel increments. The measurements are then combined to construct a measurement with higher spatial resolution. Initial results obtained while implementing a similar process used to increase the spatial resolution of measurements made with a commercially available Fizeau interferometer will be presented.

Mooney, James T.↗