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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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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Separation of crack extension modes in orthotropic delamination models

In the analysis of an interface crack between dissimilar elastic materials, the mode of crack extension is typically not unique, due to oscillatory behavior of near-tip stresses and displacements. This behavior currently limits the applicability of interfacial fracture mechanics as a means to predict composite delamination. The Virtual Crack Closure Technique (VCCT) is a method used to extract mode 1 and mode 2 energy release rates from numerical fracture solutions. The mode of crack extension extracted from an oscillatory solution using the VCCT is not unique due to the dependence of mode on the virtual crack extension length, Delta. In this work, a method is presented for using the VCCT to extract Delta-independent crack extension modes for the case of an interface crack between two in-plane orthotropic materials. The method does not involve altering the analysis to eliminate its oscillatory behavior. Instead, it is argued that physically reasonable, Delta-independent modes of crack extension can be extracted from oscillatory solutions. Knowledge of near-tip fields is used to determine the explicit Delta dependence of energy release rate parameters. Energy release rates are then defined that are separated from the oscillatory dependence on Delta. A modified VCCT using these energy release rate definitions is applied to results from finite element analyses, showing that Delta-independent modes of crack extension result. The modified technique has potential as a consistent method for extracting crack extension modes from numerical solutions. The Delta-independent modes extracted using this technique can also serve as guides for testing the convergence of finite element models. Direct applications of this work include the analysis of planar composite delamination problems, where plies or debonded laminates are modeled as in-plane orthotropic materials.

Beuth, Jack L.↗
NASA NTRS2008

Active Metal Brazing and Characterization of Brazed Joints in C-C and C-SiC Composites to Copper-Clad-Molybdenum System

Carbon/carbon composites with CVI and resin-derived matrices, and C/SiC composites reinforced with T-300 carbon fibers in a CVI SiC matrix were joined to Cu-clad Mo using two Ag-Cu braze alloys, Cusil-ABA (1.75% Ti) and Ticusil (4.5% Ti). The brazed joints revealed good interfacial bonding, preferential precipitation of Ti at the composite/braze interface, and a tendency toward delamination in resin-derived C/C composite. Extensive braze penetration of the inter-fiber channels in the CVI C/C composites was observed. The Knoop microhardness (HK) distribution across the C/C joints indicated sharp gradients at the interface, and a higher hardness in Ticusil than in Cusil-ABA. For the C/SiC composite to Cu-clad-Mo joints, the effect of composite surface preparation revealed that ground samples did not crack whereas unground samples cracked. Calculated strain energy in brazed joints in both systems is comparable to the strain energy in a number of other ceramic/metal systems. Theoretical predictions of the effective thermal resistance suggest that such joined systems may be promising for thermal management applications.

Singh, M.↗
DOE OSTI2022

Revealing nanomechanical deformation at the interface and degradation in all-thin-film inorganic electrochromic devices

Recently, progress in electrochromic (EC) devices has been made in optimizing electrode and device configurations and performance. However, the ion insertion/de-insertion induced charge transfer (CT) nanomechanical effect has remained unexplored, i.e., repetitive electrode size changes at the nanoscale and stress/strain generated during electrochemical cycling, which is the focus of this work due to its intimate correlation with the elastic and plastic deformation at the interface. Considering the intervalence electrons, excellent electrochemical kinetics, and dramatic color changes, tungsten oxide (WO 3 ) and nickel oxide (NiO) films are configured as the EC cathode and anode materials, respectively, within a full device. Upon extended cycles (>10 000), the void generation and delamination that occurred at the interface account for performance decay. Encouraged by the findings, nanoindentation mechanical tests and electrical kelvin probe force microscopy were employed to investigate the CT induced effects at the interface. There is a dramatic increase of up to 45% in the elastic Young's modulus in colored/charged WO 3 at ~40 mC cm -2 . Here, the correlation between CT and synergistic mechanical effect is interpreted by the Lippman equation. Interestingly, despite the charged state (colored; lithiated) with a relatively flat morphology bringing an ~3.4 times higher electrostatic surface potential, the electrical work function unexpectedly decreases, arising from the dominant effect of the dipole layer potential over the chemical potential. The interatomic cohesive energy and equilibrium distance increase bury the seeds for mechanical deformation in the long run. This work provides fundamental insights into electro-chemo mechanics and interdisciplinary concerted interfacial effects at the nano/atomic level. The dependence of surface potential, stress, work function, and cohesive energy on electrochemical kinetics has been interpreted.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Analysis of local delaminations caused by angle ply matrix cracks

Two different families of graphite/epoxy laminates with similar layups but different stacking sequences, (0,theta,-theta) sub s and (-theta/theta/0) sub s were analyzed using three-dimensional finite element analysis for theta = 15 and 30 degrees. Delaminations were modeled in the -theta/theta interface, bounded by a matrix crack and the stress free edge. The total strain energy release rate, G, along the delamination front was computed using three different techniques: the virtual crack closure technique (VCCT), the equivalent domain Integral (EDI) technique, and a global energy balance technique. The opening fracture mode component of the strain energy release rate, Gl, along the delamination front was also computed for various delamination lengths using VCCT. The effect of residual thermal and moisture stresses on G was evaluated.

Salpekar, Satish A.↗
NASA NTRS2023

Characterization of Low-Velocity Impact Damage in Thermoplastic Laminated Composites

The impact damage response of two thermoplastic material systems were compared over a range of impact energies. Eight-inch-square impact specimens with a 24-ply quasi-isotropic layup were manufactured from TC1225 LMPAEK T700G from Toray Industries and APC AS4D/PEKK-FC from Solvay. The effect of the degree of crystallinity (DOC) on the damage response was also investigated using a third set of specimens from the Toray material manufactured with reduced crystallinity. Using a combination of data obtained from X-ray computed tomography (CT) scans and ultrasonic testing (UT), detailed damage maps were created for every interface and ply for selected specimens. Using these damage maps, the delamination size, shape, and area were evaluated at each interface. The presence of fractured fibers was also identified on each ply. The LMPAEK material was found to have fewer and smaller delaminations than the PEKK specimens for impacts at the same energy. However, the LMPAEK specimens contained a larger number of fiber breaks. A similar trend was observed when comparing the baseline LMPAEK specimens with the low-crystallinity LMPAEK specimens. The low-crystallinity specimens had very little delamination but had a large number of plies with fiber breaks. In addition, the LMPAEK specimens often contained lines of fiber fractures in near-surface plies emanating from the contact region that were not present in the PEKK specimens.

Composite Materials↗
NASA NTRS2023

Characterization of Low-Velocity Impact Damage in Thermoplastic Laminated Composites

The impact damage response of two thermoplastic material systems were compared over a range of impact energies. Eight-inch-square impact specimens with a 24-ply quasi-isotropic layup were manufactured from TC1225 LMPAEK T700G from Toray Industries and APC AS4D/PEKK-FC from Solvay. The effect of the degree of crystallinity (DOC) on the damage response was also investigated using a third set of specimens from the Toray material manufactured with reduced crystallinity. Using a combination of data obtained from X-ray computed tomography (CT) scans and ultrasonic testing (UT), detailed damage maps were created for every interface and ply for selected specimens. Using these damage maps, the delamination size, shape, and area were evaluated at each interface. The presence of fractured fibers was also identified on each ply. The LMPAEK material was found to have fewer and smaller delaminations than the PEKK specimens for impacts at the same energy. However, the LMPAEK specimens contained a larger number of fiber breaks. A similar trend was observed when comparing the baseline LMPAEK specimens with the low-crystallinity LMPAEK specimens. The low-crystallinity specimens had very little delamination but had a large number of plies with fiber breaks. In addition, the LMPAEK specimens often contained lines of fiber fractures in near-surface plies emanating from the contact region that were not present in the PEKK specimens.

Composite Materials↗
NASA NTRS2015

An Enriched Shell Element for Delamination Simulation in Composite Laminates

A formulation is presented for an enriched shell finite element capable of delamination simulation in composite laminates. The element uses an adaptive splitting approach for damage characterization that allows for straightforward low-fidelity model creation and a numerically efficient solution. The Floating Node Method is used in conjunction with the Virtual Crack Closure Technique to predict delamination growth and represent it discretely at an arbitrary ply interface. The enriched element is verified for Mode I delamination simulation using numerical benchmark data. After determining important mesh configuration guidelines for the vicinity of the delamination front in the model, a good correlation was found between the enriched shell element model results and the benchmark data set.

McElroy, Mark↗
DOE OSTI2023

Fundamental study of gas species transport in the oxygen electrode of solid oxide fuel and electrolysis cells

A fundamental analysis of multicomponent gas transport models was performed in application to the oxygen electrodes of solid oxide cells. It is common practice to neglect the effect of pressure gradients within oxygen electrodes, even though a net molar flux at the electrolyte surface implies that a pressure gradient must exist. The influence of both Darcy velocity and Knudsen flux are considered in the context of ordinary (Fickian) diffusion, the dusty gas model, and the binary friction model. Comparisons between the models and different sets of assumptions are made via parametric studies on operating load, oxygen partial pressure, microstructural properties, and electrode thickness. Results show that the pressure gradient will have a significant impact on the oxygen concentration distribution and therefore the concentration overpotential. In electrolysis mode, pressure increases up to 1 atm are predicted, indicating that pressure at the electrode/electrolyte interface could contribute to electrode delamination. Additionally, it is found that Darcy's law is insufficient for calculating the pressure distribution without accounting for the flux due to Knudsen diffusion. Additionally, it is found that for the range of properties typical of oxygen electrodes, there is a negligibly small difference between the dusty gas model and binary friction model from a practical standpoint.

08 HYDROGEN↗
NASA NTRS1983

An evaluation of the effects of stacking sequence and thickness on the fatigue life of quasi-isotropic graphite/epoxy laminates

Notched and unnotched geometries at 16, 32, and 64-ply thicknesses of a 90/45/0-45 (ns) laminate and a 45/0/-45/90 (ns) laminate were tested in compression-compression fatigue. The fatigue life and the initiation, type, and progression of damage were determined. Interlaminar stresses generated at straight, free edges of axially loaded laminates were used to interpret the test results. The fatigue lives of the notched specimens did not appear to be a strong function of laminate stacking sequence or specimen thickness. The stress concentration at the hole dominated over the interlaminar stresses at the straight free edge. The unnotched specimens of the 90/45/0/-45 (ns) laminate with tensile interlaminar normal stresses delaminated more readily than did the 45/0/-45/90 (ns) laminate with compressive interlaminar normal stress. The life of the 16-ply unnotched specimens was lower than the 32- and 64-ply specimens. Delaminations were located at the interface where the maximum shear stress occurred regardless of the sense or magnitude of the interlaminar normal stress. An antibuckling fixture was effective in preventing out-of-plane motion without overconstraining the specimen.

Harris, C. E.↗
NASA NTRS1985

An evaluation of the effects of stacking sequence and thickness on the fatigue life of quasi-isotropic graphite/epoxy laminates

Notched and unnotched geometries at 16, 32, and 64-ply thicknesses of a 90/45/0-45 (ns) laminate and a 45/0/-45/90 (ns) laminate were tested in compression-compression fatigue. The fatigue life and the initiation, type, and progression of damage were determined. Interlaminar stresses generated at straight, free edges of axially loaded laminates were used to interpret the test results. The fatigue lives of the notched specimens did not appear to be a strong function of laminate stacking sequence or specimen thickness. The stress concentration at the hole dominated over the interlaminar stresses at the straight free edge. The unnotched specimens of the 90/45/0/-45 (ns) laminate with tensile interlaminar normal stresses delaminated more readily than did the 45/0/-45/90 (ns) laminate with compressive interlaminar normal stress. The life of the 16-ply unnotched specimens was lower than the 32and 64-ply specimens. Delaminations were located at the interface where the maximum shear stress occurred regardless of the sense or magnitude of the interlaminar normal stress. An antibuckling fixture was effective in preventing out-of-plane motion without overconstraining the specimen.

Harris, C. E.↗
NASA NTRS2006

Porous Media Approach for Modeling Closed Cell Foam

In order to minimize boil off of the liquid oxygen and liquid hydrogen and to prevent the formation of ice on its exterior surface, the Space Shuttle External Tank (ET) is insulated using various low-density, closed-cell polymeric foams. Improved analysis methods for these foam materials are needed to predict the foam structural response and to help identify the foam fracture behavior in order to help minimize foam shedding occurrences. This presentation describes a continuum based approach to modeling the foam thermo-mechanical behavior that accounts for the cellular nature of the material and explicitly addresses the effect of the internal cell gas pressure. A porous media approach is implemented in a finite element frame work to model the mechanical behavior of the closed cell foam. The ABAQUS general purpose finite element program is used to simulate the continuum behavior of the foam. The soil mechanics element is implemented to account for the cell internal pressure and its effect on the stress and strain fields. The pressure variation inside the closed cells is calculated using the ideal gas laws. The soil mechanics element is compatible with an orthotropic materials model to capture the different behavior between the rise and in-plane directions of the foam. The porous media approach is applied to model the foam thermal strain and calculate the foam effective coefficient of thermal expansion. The calculated foam coefficients of thermal expansion were able to simulate the measured thermal strain during heat up from cryogenic temperature to room temperature in vacuum. The porous media approach was applied to an insulated substrate with one inch foam and compared to a simple elastic solution without pore pressure. The porous media approach is also applied to model the foam mechanical behavior during subscale laboratory experiments. In this test, a foam layer sprayed on a metal substrate is subjected to a temperature variation while the metal substrate is stretched to simulate the structural response of the tank during operation. The thermal expansion mismatch between the foam and the metal substrate and the thermal gradient in the foam layer causes high tensile stresses near the metal/foam interface that can lead to delamination.

Ghosn, Louis J.↗
NASA NTRS2014

Damage Simulation in Non-Crimp Fabric Composite Plates Subjected to Impact Loads

Progressive failure analysis (PFA) of non-crimp fabric (NCF) composite laminates subjected to low velocity impact loads was performed using the COmplete STress Reduction (COSTR) damage model implemented through VUMAT and UMAT41 user subroutines in the frame works of the commercial finite element programs ABAQUS/Explicit and LS-DYNA, respectively. To validate the model, low velocity experiments were conducted and detailed correlations between the predictions and measurements for both intra-laminar and inter-laminar failures were made. The developed material and damage model predicts the peak impact load and duration very close with the experimental results. Also, the simulation results of delamination damage between the ply interfaces, in-plane matrix damages and fiber damages were all in good agreement with the measurements from the non-destructive evaluation data.

Satyanarayana, Arunkumar↗
NASA NTRS2018

Simulating the Clamped Tapered Beam Specimen Under Quasi-Static and Fatigue Loading Using Floating Node Method

As part of the NASA Advanced Composites Project (ACP), a sub-element has been designed to provide validation data for progressive damage analysis models. The clamped tapered beam is a cross-ply laminated composite specimen designed to validate the simulation of the onset of matrix cracks and their interaction with delaminations, including delamination migration. A tapered geometry was used to localize the first damage occurrence in the tapered region, without prescribing an initial crack. The boundary and loading conditions were chosen to favor delamination growth and subsequent migration after the first damage occurrence. The typical sequence of events consists of a matrix crack located at the tapered region, leading to delamination onset, followed by delamination growth and subsequent delamination migration to a different interface via a dominant matrix crack. The Clamped Tapered Beam (CTB) was tested in both quasi-static and fatigue regimes. The results obtained are used in this study to assess and validate a methodology based on the Floating Node Method (FNM) implemented as an Extended Interface Element. In this methodology, quasi-static and fatigue damage formation and development are modeled by combining FNM to represent crack networks, with Directional Cohesive Zone Elements (DCZE) and Virtual Crack Closure Technique (VCCT), respectively. Qualitatively, the methodology is capable of predicting the sequence of events and overall failure morphology. Quantitatively, the simulation results generally bound the experimental data, based on the range of the characterization data used. In this paper, the results from quasi static and fatigue simulations are compared and correlated with experimental data.

Seshadri, B. R.↗
NASA NTRSDate not supplied

Temperature Mapping Above and Below Thermal Barrier Coatings Using Phosphor Thermometry

Luminescence lifetime imaging was obtained from thin Er-doped yttria-stabilized zirconia (YSZ:Er) layers integrated into either the top or bottom of thermal barrier coatings (TBCs) to produce temperature maps from either the TBC surface or from the TBC/substrate interface. Temperature mapping was combined with luminescence intensity-based delamination monitoring to quantitatively assess the degradation of thermal protection associated with localized TBC delamination. Temperature mapping of either the TBC surface or TBC/substrate interface during air film cooling was also performed to evaluate the effectiveness of air film cooling both at the TBC surface as well as the cooling effectiveness at the TBC/substrate interface.

phosphor thermometry↗
NASA NTRS1989

Finite element modeling of frictionally restrained composite interfaces

The use of special interface finite elements to model frictional restraint in composite interfaces is described. These elements simulate Coulomb friction at the interface, and are incorporated into a standard finite element analysis of a two-dimensional isolated fiber pullout test. Various interfacial characteristics, such as the distribution of stresses at the interface, the extent of slip and delamination, load diffusion from fiber to matrix, and the amount of fiber extraction or depression are studied for different friction coefficients. The results are compared to those obtained analytically using a singular integral equation approach, and those obtained by assuming a constant interface shear strength. The usefulness of these elements in micromechanical modeling of fiber-reinforced composite materials is highlighted.

Ballarini, Roberto↗
NASA NTRS2004

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.↗
NASA NTRS2001

Decohesion Elements using Two and Three-Parameter Mixed-Mode Criteria

An eight-node decohesion element implementing different criteria to predict delamination growth under mixed-mode loading is proposed. The element is used at the interface between solid finite elements to model the initiation and propagation of delamination. A single displacement-based damage parameter is used in a softening law to track the damage state of the interface. The power law criterion and a three-parameter mixed-mode criterion are used to predict delamination growth. The accuracy of the predictions is evaluated in single mode delamination and in the mixed-mode bending tests.

Davila, Carlos G.↗
NASA NTRS2005

Detection and Characterization of Flaws in Sprayed on Foam Insulation with Pulsed Terahertz Frequency Electromagnetic Waves

The detection and repair of flaws such as voids and delaminations in the sprayed on foam insulation of the external tank reduces the probability of foam debris during shuttle ascent. The low density of sprayed on foam insulation along with it other physical properties makes detection of flaws difficult with conventional techniques. An emerging technology that has application for quantitative evaluation of flaws in the foam is pulsed electromagnetic waves at terahertz frequencies. The short wavelengths of these terahertz pulses make them ideal for imaging flaws in the foam. This paper examines the application of terahertz pulses for flaw detection in foam characteristic of the foam insulation of the external tank. Of particular interest is the detection of voids and delaminations, encapsulated in the foam or at the interface between the foam and a metal backing. The technique is shown to be capable of imaging small voids and delaminations through as much as 20 cm of foam. Methods for reducing the temporal responses of the terahertz pulses to improve flaw detection and yield quantitative characterizations of the size and location of the flaws are discussed.

Winfree, William P.↗