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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 NTRS2016

Design and Use of a Guided Weight Impactor to Impart Barely Visible Impact Damage

Aircraft structure is required to demonstrate satisfaction of the FAR requirements for Category 1, such as barely visible impact damage (BVID). Typical aircraft structure is impacted using a dropped weight impactor, which can impart BVID to the top surface of the structure. A recent test of a multi-bay box (MBB) composite test article, that represents an 80% scale center section of a hybrid wing body aircraft, required impact to be in a direction other than vertical from above, but still in an direction that is normal to the surface. This requirement eliminated the use of the conventional dropped weight impactor. Therefore, a design study was undertaken to determine the most effective way to efficiently and reliably impact the MBB. The chosen design was a guided weight impactor that is gravity driven. This paper describes the design of the guided weight impactor, and presents the results of its use for imparting BVID to the MBB. The guided weight impactor was seen to be a very reliable method to impart BVID, while at the same time having the capability to be highly configurable for use on other aircraft structure that is impacted at a variety of impact energies and from a variety of directions.

Lovejoy, Andrew E.↗
NASA NTRS1993

Impact damage in filament wound composite bottles

Increasingly, composite materials are being used in advanced structural applications because of the significant weight savings they offer when compared to more traditional engineering materials. The higher cost of composites must be offset by the increased performance that results from reduced structural weight if these new materials are to be used effectively. At present, there is considerable interest in fabricating solid rocket motor cases out of composite materials, and capitalizing on the reduced structural weight to increase rocket performance. However, one of the difficulties that arises when composite materials are used is that composites can develop significant amounts of internal damage during low velocity impacts. Such low velocity impacts may be encountered in routine handling of a structural component like a rocket motor case. The ability to assess the reduction in structural integrity of composite motor cases that experience accidental impacts is essential if composite rocket motor cases are to be certified for manned flight. While experimental studies of the post-impact performance of filament wound composite motor cases haven been proven performed (2,3), scaling impact data from small specimens to full scale structures has proven difficult. If such a scaling methodology is to be achieved, an increased understanding of the damage processes which influence residual strength is required. The study described herein was part of an ongoing investigation of damage development and reduction of tensile strength in filament wound composites subjected to low velocity impacts. The present study, which focused on documenting the damage that develops in filament wound composites as a result of such impacts, included two distinct tasks. The first task was to experimentally assess impact damage in small, filament wound pressure bottles using x-ray radiography. The second task was to study the feasibility of using digital image processing techniques to assist in determining the 3-D distribution of damage from stereo x-ray pairs.

Highsmith, Alton L.↗
NASA NTRS1991

Developments in impact damage modeling for laminated composite structures

Damage tolerance is the most critical technical issue for composite fuselage structures studied in the Advanced Technology Composite Aircraft Structures (ATCAS) program. The objective here is to understand both the impact damage resistance and residual strength of the laminated composite fuselage structure. An understanding of the different damage mechanisms which occur during an impact event will support the selection of materials and structural configurations used in different fuselage quadrants and guide the development of analysis tools for predicting the residual strength of impacted laminates. Prediction of the damage state along with the knowledge of post-impact response to applied loads will allow for engineered stacking sequencies and structural configurations; intelligent decisions on repair requirements will also result.

Dost, Ernest F.↗
NASA NTRS2016

Engineering Polymer Blends for Impact Damage Mitigation

Structures containing polymers such as DuPont's Surlyn® 8940, demonstrate puncture healing when impacted by a 9 millimeter projectile traveling from speeds near 300 meters per second (1,100 feet per second) to hypervelocity impacts in the micrometeoroid velocity range of 5 kilometers per second (16,000 feet per second). Surlyn® 8940 puncture heals over a temperature range of minus 30 degrees Centigrade to plus 70 degrees Centigrade and shows potential for use in pressurized vessels subject to impact damage. However, such polymers are difficult to process and limited in applicability due to their low thermal stability, poor chemical resistance and overall poor mechanical properties. In this work, several puncture healing engineered melt formulations were developed. Moldings of melt blend formulations were impacted with a 5.56 millimeter projectile with a nominal velocity of 945 meters per second (3,100 feet per second) at about 25 degrees Centigrade, 50 degrees Centigrade and 100 degrees Centigrade, depending upon the specific blend being investigated. Self-healing tendencies were determined using surface vacuum pressure tests and tensile tests after penetration using tensile dog-bone specimens (ASTM D 638-10). For the characterization of tensile properties both pristine and impacted specimens were tested to obtain tensile modulus, yield stress and tensile strength, where possible. Experimental results demonstrate a range of new puncture healing blends which mitigate damage in the ballistic velocity regime.

Gordon, Keith L.↗
NASA NTRS2004

Acoustic Emission Detection of Impact Damage on Space Shuttle Structures

The loss of the Space Shuttle Columbia as a result of impact damage from foam debris during ascent has led NASA to investigate the feasibility of on-board impact detection technologies. AE sensing has been utilized to monitor a wide variety of impact conditions on Space Shuttle components ranging from insulating foam and ablator materials, and ice at ascent velocities to simulated hypervelocity micrometeoroid and orbital debris impacts. Impact testing has been performed on both reinforced carbon composite leading edge materials as well as Shuttle tile materials on representative aluminum wing structures. Results of these impact tests will be presented with a focus on the acoustic emission sensor responses to these impact conditions. These tests have demonstrated the potential of employing an on-board Shuttle impact detection system. We will describe the present plans for implementation of an initial, very low frequency acoustic impact sensing system using pre-existing flight qualified hardware. The details of an accompanying flight measurement system to assess the Shuttle s acoustic background noise environment as a function of frequency will be described. The background noise assessment is being performed to optimize the frequency range of sensing for a planned future upgrade to the initial impact sensing system.

Prosser, William H.↗
NASA NTRS2019

The Effect of Impact Damage Next to Holes on the Bearing Strength of Carbon Fiber Laminates

This study was undertaken as a follow-on to a previous study that examined the effect of hole quality in the bearing strength of carbon fiber laminates. After the author of that previous study had established that hole quality had little effect on the ultimate bearing strength for carbon fiber laminates, the question was raised as to the effects of impact damage next to a hole on the bearing strength of that hole. While this is an unlikely scenario, it is still possible that this may occur on a launch vehicle structure and thus warranted study. After a literature review, results of a few studies on the hole-impact interaction with respect to resulting damage for carbon fiber laminates were found, but none that specifically addressed the resulting bearing strength. In reference 2, it was found that the holes and impact could interact to develop matrix splits. However, the lay-ups used in this study consisted of clumped plies [04/904]S, which are much more prone to matrix splitting than a laminate that would actually be used in practice (such as a lay-up of [0/90]4S). This study also focused on the analytical aspects of the problem rather than the experimental results. Reference 3 also used [04/904]S laminates (clumped plies) and examined the damage morphology, determining that, as the impact damage neared the hole, the damage zone became more asymmetrical. The effect this would have on bearing strength was not addressed. The experimental work presented in this study was to develop empirical data relating holeimpact damage effects on the resulting bearing strength of a commonly used (quasi-isotropic) lay-up of carbon fiber laminate. The emphasis was not on the morphology of the resulting damage, as it was in references 2 and 3, but rather on the practical aspects of how this damage affected the bearing strength and how this compared to the companion study1 on the effect of hole quality on the bearing strength of the laminate.

Nettles, A. T.↗
NASA NTRS1991

Effects of stacking sequence on impact damage resistance and residual strength for quasi-isotropic laminates

Residual strength of an impacted composite laminate is dependent on details of the damage state. Stacking sequence was varied to judge its effect on damage caused by low-velocity impact. This was done for quasi-isotropic layups of a toughened composite material. Experimental observations on changes in the impact damage state and postimpact compressive performance were presented for seven different laminate stacking sequences. The applicability and limitations of analysis compared to experimental results were also discussed. Postimpact compressive behavior was found to be a strong function of the laminate stacking sequence. This relationship was found to depend on thickness, stacking sequence, size, and location of sublaminates that comprise the impact damage state. The postimpact strength for specimens with a relatively symmetric distribution of damage through the laminate thickness was accurately predicted by models that accounted for sublaminate stability and in-plane stress redistribution. An asymmetric distribution of damage in some laminate stacking sequences tended to alter specimen stability. Geometrically nonlinear finite element analysis was used to predict this behavior.

Dost, Ernest F.↗
NASA NTRS1984

Single-drop impact damage prediction for low density, coated ceramic materials

A technique utilizing finite element analysis, liquid impact kinematics, and momentum theory is described and compared to single-drop impact test data performed on various configurations of coated ceramic material. The method correlates well with test data and is useful in predicting the single-drop impact damage velocity threshold for low-density, coated ceramic materials.

Mustelier, D.↗
NASA NTRS1989

On modelling the residual strength of impact damaged, compression loaded laminates

A methodology is presented to predict the residual compression strength of impact damaged composite laminates by considering the competing failure modes of local delamination buckling and compression failure. The minimum delamination buckling load and the location of the first local region to buckle are determined by a Rayleigh-Ritz analysis. The Rayleigh-Ritz analysis is formulated to account for the multiple delamination locations, Poisson's ratio mismatch between sublaminates and possible bending-stretching coupling behavior of the delaminated regions. The compression failure load is determined by a modified maximum strain criterion applied in the delaminated region. The minimum delamination buckling and compression failure loads may be compared to the global buckling load to predict initial failure. For non-catastrophic failures, failure sequences are predicted in an iterative manner. Analytical predictions for sequential failure modes and loads are shown to correlate well with experimental results. A comparative evaluation of various delamination buckling models and their accuracy in predicting experimental results is also presented.

Davidson, B. D.↗
NASA NTRS2006

Quasi-Static 3-Point Reinforced Carbon-Carbon Bend Test and Analysis for Shuttle Orbiter Wing Leading Edge Impact Damage Thresholds

Static 3-point bend tests of Reinforced Carbon-Carbon (RCC) were conducted to failure to provide data for additional validation of an LS-DYNA RCC model suitable for predicting the threshold of impact damage to shuttle orbiter wing leading edges. LS-DYNA predictions correlated well with the average RCC failure load, and were good in matching the load vs. deflection. However, correlating the detectable damage using NDE methods with the cumulative damage parameter in LS-DYNA material model 58 was not readily achievable. The difficulty of finding internal RCC damage with NDE and the high sensitivity of the mat58 damage parameter to the load near failure made the task very challenging. In addition, damage mechanisms for RCC due to dynamic impact of debris such as foam and ice and damage mechanisms due to a static loading were, as expected, not equivalent.

Fasanella, Edwin L.↗
NASA NTRS1987

Investigation of low velocity impact damage on filamentary composite materials

Presented are the results of an investigation of the effect of low velocity impact on the residual modulus and residual strength of flat filamentary composite materials. Theoretical analysis of composite materials indicates that the modulus of the material must decrease as impact damage increases. This decrease must also correlate to the decrease in residual strength. This study attempts to verify these hypotheses. Graphite/epoxy laminates (AS4/3501-6) of various fiber orientations (8 (0 deg), 2 (+ or - 45 deg)sub 8) were impacted using a falling weight impact tester. Impact energies ranged from 0.42 to 1.55 ft-lb, with impact velocities from 2.03 to 3.98 ft/sec. The results show that there is a reduction in residual modulus of the plate as the impact energy increases.

Bower, Mark V.↗
NASA NTRS1995

A Neural Network/Acoustic Emission Analysis of Impact Damaged Graphite/Epoxy Pressure Vessels

Acoustic emission (AE) signal analysis has been used to measure the effects of impact damage on burst pressure in 5.75 inch diameter, inert propellant filled, filament wound pressure vessels. The AE data were collected from fifteen graphite/epoxy pressure vessels featuring five damage states and three resin systems. A burst pressure prediction model was developed by correlating the AE amplitude (frequency) distribution, generated during the first pressure ramp to 800 psig (approximately 25% of the average expected burst pressure for an undamaged vessel) to known burst pressures using a four layered back propagation neural network. The neural network, trained on three vessels from each resin system, was able to predict burst pressures with a worst case error of 5.7% for the entire fifteen bottle set.

Walker, James L.↗
NASA NTRS1992

Impact damage in small diameter graphite/epoxy composite struts

An investigation was performed to study impact induced damage in small-diameter struts made of a composite material with a brittle matrix system. The major focus is on characterizing the impact behavior associated with the barely visible damage. An experimental procedure including ultrasonic inspection, instrumented impact testing, and delamination buckling and residual strength measurements is presented. From the ultrasonic inspection, it is found that for the strut specimens under investigation, the impact energy level for barely visible damage threshold is above that of the internal damage threshold. A 60- to 65-percent reduction in compressive strength was typical for struts subjected to the barely visible impact damage threshold.

Chen, G.-S.↗
NASA NTRS2020

Mechanics-Based Modeling Approach for Rapid Prediction of Low Velocity Impact Damage in Composite Laminates

A mechanics-based modeling approach is developed to rapidly predict damage in polymer matrix composites resulting from a low velocity impact event. The approach is incorporated into a computer code that provides an efficient means to assess the damage resistance for a range of material systems, layup configurations, and impact scenarios. It is envisioned that the developed approach will aid in early design and analysis of composite structures where sizing and layup decisions must be made, and evaluating the feasibility of a large number of laminate configurations using numerical approaches such as finite element analysis (FEA) is prohibitively expensive. Therefore, the goal of the modeling approach is to predict the impact damage size given the laminate configuration and impact scenario. This information can then be used to determine the residual strength of the material. To be useful in such a context, the tool is designed to run quickly (<2 minutes) to allow a large number of design cases to be investigated. The results presented demonstrate that the model is capable of efficiently predicting low velocity impact damage size, shape, and location within an acceptable accuracy suitable for preliminary design and analysis of composite structures.

Borkowski, Luke↗
NASA NTRS1982

Effect of resin on impact damage tolerance of graphite/epoxy laminates

Twenty-four different epoxy resin systems were evaluated by a variety of test techniques to identify materials that exhibited improved impact damage tolerance in graphite/epoxy composite laminates. Forty-eight-ply composite panels of five of the material systems were able to sustain 100 m/s impact by a 1.27-cm-diameter aluminum projectile while statically loaded to strains of 0.005. Of the five materials with the highest tolerance to impact, two had elastomeric additives, two had thermoplastic additives, and one had a vinyl modifier; all the five systems used bisphenol A as the base resin. An evaluation of test results shows that the laminate damage tolerance is largely determined by the resin tensile properties, and that improvements in laminate damage tolerance are not necessarily made at the expense of room-temperature mechanical properties. The results also suggest that a resin volume fraction of 40 percent or greater may be required to permit the plastic flow between fibers necessary for improved damage tolerance.

Williams, J. G.↗
NASA NTRS1995

Impact damage in composite plates

The objective of this research paper was to link two computer codes, PDCOMP (for Progressive Damage Analysis for Laminated Composites) and 3DIMPACT (for the prediction of the extent of delaminations in laminated composites resulting from point impact loads), in order to predict impact damage by taking into account local damage and material degradation and to estimate residual stiffness of composites after impact. The resulting graphs and analysis versus test results are presented along with the conclusive results of the codes' performances.

Shahid, I.↗
NASA NTRS1980

Ultrasonic nondestructive evaluation of impact-damaged graphite fiber composite

Unidirectional Hercules AS/3501-6 graphite fiber epoxy composites were subjected to repeated controlled low-velocity drop weight impacts in the laminate direction. The degradation was ultrasonically monitored using through-thickness attenuation and a modified stress wave factor (SWF). There appears to be strong correlations between the number of drop-weight impacts, the residual tensile strength, the through-thickness attenuation, and the SWF. The results are very encouraging with respect to the NDE potential of both of these ultrasonic parameters to provide strength characterizations in virgin as well as impact-damaged fiber composite structures.

Williams, J. H., Jr.↗