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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Micromechanics, Fracture Mechanics and Gas Permeability of Composite Laminates for Cryogenic Storage Systems

A micromechanics method is developed to investigate microcrack propagation in a liquid hydrogen composite tank at cryogenic temperature. The unit cell is modeled using square and hexagonal shapes depends on fiber and matrix layout from microscopic images of composite laminates. Periodic boundary conditions are applied to the unit cell. The temperature dependent properties are taken into account in the analysis. The laminate properties estimated by the micromechanics method are compared with empirical solutions using constituent properties. The micro stresses in the fiber and matrix phases based on boundary conditions in laminate level are calculated to predict the formation of microcracks in the matrix. The method is applied to an actual liquid hydrogen storage system. The analysis predicts micro stresses in the matrix phase are large enough to cause microcracks in the composite. Stress singularity of a transverse crack normal to a ply-interface is investigated to predict the fracture behavior at cryogenic conditions using analytical and finite element analysis. When a transverse crack touches a ply-interface of a composite layer with same fiber orientation, the stress singularity is equal to 1/2. When the transverse crack propagates to a stiffer layer normal to the ply-direction, the singularity becomes less than 1/2 and vice versa. Finite element analysis is performed to predict the fracture toughness of a laminated beam subjected to fracture loads measured by four-point bending tests at room and cryogenic temperatures. As results, the fracture load at cryogenic temperature is significantly lower than that at room temperature. However, when thermal stresses are taken into consideration, for both cases of room and cryogenic temperatures, the difference of the fracture toughness becomes insignificant. The result indicates fracture toughness is a characteristic property, which is independent to temperature changes. The experimental analysis is performed to investigate the effect of cryogenic cycling on permeability for various composite material systems. Textile composites have lower permeability than laminated composites even with increasing number of cryogenic cycle. Nano-particles dispersed in laminated composites do not show improvement on permeability. The optical inspection is performed to investigate the microcrack propagation and void content in laminated composites and compared the microscopic results before and after cryogenic cycling.

Choi, Sukjoo↗
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.↗
DOE OSTI2015

Characterization of Contact and Bulk Thermal Resistance of Laminations for Electric Machines

Thermal management for electric motors is important as the automotive industry continues to transition to more electrically dominant vehicle propulsion systems. The transition to more electrically dominant propulsion systems leads to higher-power duty cycles for electric-drive systems. Thermal constraints place significant limitations on how electric motors ultimately perform. As thermal management improves, there will be a direct trade-off among motor performance, efficiency, cost, and the sizing of electric motors to operate within the thermal constraints. During the development of thermal finite element analysis models and computational fluid dynamics models for electric motors, it was found that there was a lack of open literature detailing the thermal properties of key materials common in electric motors that are significant in terms of heat removal. The lack of available literature, coupled with the strong interest from industry in the passive-stack thermal measurement results, led to experiments to characterize the thermal contact resistance between motor laminations. We examined four lamination materials, including the commonly used 26 gauge and 29 gauge M19 materials, the HF10 and Arnon 7 materials. These latter two materials are thinner and reduce eddy currents responsible for core losses. We measured the thermal conductivity of the lamination materials and the thermal contact resistance between laminations in a stack, as well as investigated factors affecting contact resistance between laminations such as the contact pressure and surface finish. Lamination property data will be provided and we also develop a model to estimate the through-stack thermal conductivity for materials beyond those that were directly tested in this work. For example, at a clamping pressure of 138 kPa, the 29 gauge M19 material has a through-stack thermal conductivity of 1.68 W/m-K, and the contact resistance between laminations was measured to be 193 mm^2-K/W. The measured bulk thermal conductivity for the M19 29 gauge material is 21.0 W/m-K. Density and specific heat were measured to be 7450 kg/m^3 and 463 J/kg-K, respectively. These results are helping, and will continue to help engineers and researchers in the design and development of motors.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Reducing Thermal Degradation of Perovskite Solar Cells during Vacuum Lamination by Internal Diffusion Barriers

Current photovoltaic (PV) panels typically contain interconnected solar cells that are vacuum laminated with a polymer encapsulant between two pieces of glass or glass with a polymer backsheet. This packaging approach is ubiquitous in conventional photovoltaic technologies such as silicon and thinfilm solar modules, contributing to thermal management, mechanical reinforcement, and environmental protection to enable the long lifetimes necessary to become financially acceptable. Commercial vacuum lamination processes typically occur at 150 °C to ensure cross-linking and/or glass bonding of the encapsulant to the glass and PV cells. Perovskite solar cells (PSCs) have emerged as a promising next-generation PV technology that is known to degrade under thermal stresses, especially at temperatures above 100 °C. In this study, we determine degradation modes during lamination and engineer internal diffusion barriers within the PSC to withstand the harsh thermal conditions of vacuum lamination. PSCs with self-assembled monolayers at the ITO interface and SnO X layers deposited by atomic layer deposition at the electron extraction side of the device endured vacuum lamination at conditions typical of commercial PV processes (150 °C) without degradation. This work demonstrates that perovskite PV can be integrated into the existing module lamination process, enabling future single- and multijunction modules utilizing perovskite absorbers.

14 SOLAR ENERGY↗
DOE OSTI2021

An FEM-Based Peridynamic Model for Failure Analysis of Unidirectional Fiber-Reinforced Laminates

To predict the mixed damage modes of unidirectional fiber-reinforced polymer (FRP) laminates under dynamic loading, an FEM-based peridynamic model is introduced in this paper. Based on its geometric structure and material composition, a long fiber lamina is considered a transversely isotropic medium as a result of homogenization at the meso-scale. The laminated structure is modeled by stacking surface mesh layers with arbitrary fiber angles along the thickness direction. The peridynamic bonds between Gauss points connect the separated elements. These bonds are classified as inner-layer bonds and inter-layer bonds. To represent the anisotropy of a laminate, the micro-elastic modulus of the inner-layer and inter-layer bonds is calculated from the anisotropic engineering material constants separately. To capture complex failure behaviors of laminate structures, an empirical damage model is proposed for the tension/ compression breakage of peridynamic bonds. This damage model can control the in-plane and delamination failure process. Finally, benchmark tests are conducted to validate the elastic response of laminates under dynamic loading. In terms of damage analysis, the proposed model can capture the complex damage modes and resistive force of laminate structures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Failure mechanisms of cross-ply carbon fiber reinforced polymer laminates under longitudinal compression with experimental and computational analyses

Here, this study investigates the failure mechanisms of cross-ply laminates subjected to longitudinal compressive loading. A sequence of failure initiation and propagation process is observed based on optical microscopy images of failed specimens. Specifically, the failure process in the cross-ply laminates involves a combination of four failure mechanisms: fiber kinking, delamination, matrix cracking, and fiber/matrix splitting. We find that the kink-bands in the middle 0° plies of the cross-ply laminates most often show a wedge shape and the angle of matrix cracks in the 90° plies is slightly larger than that of pure 90° plies. The reason has been attributed to the constraining effects by the adjacent plies. The next focus of this study is to propose hybrid micro-macro models to more systematically study the failure mechanisms of the cross-ply laminates. We show that these models accurately predict the combined failure modes of the cross-ply laminates and enable us to closely investigate the interactions of different failure mechanisms. More importantly, the hybrid models achieve great computational efficiency compared to full-scale microstructural models. Finally, the combined experimental and computational analyses presented here provide a new level of understanding of the kink-band morphology and damage mechanisms in the cross-ply laminates.

42 ENGINEERING↗
DOE OSTI2018

Experimental characterization and modeling of thermal resistance of electric machine lamination stacks

There is lack of information in the open literature on thermal properties of electric machine lamination stacks such as contact resistance and effective thermal conductivity, yet this information is critical for researchers and engineers in electric machine design and development. The thermal conductivity of electromagnetic steel lamination materials was measured, and the thermal contact resistance between laminations in a stack, as well as factors affecting contact resistance between laminations - such as the contact pressure and surface finish - were investigated. A model was also developed to estimate the through-stack thermal conductivity for materials beyond those that were directly tested in this work. Four lamination materials were investigated, including the commonly-used 26-gauge and 29-gauge M19 materials, the HF10, and Arnon 7 materials. Although this paper focuses on electric machines for automotive applications, the information is potentially applicable to any component utilizing electromagnetic steel laminations.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Lamination of >21% Efficient Perovskite Solar Cells with Independent Process Control of Transport Layers and Interfaces

Transport layer and interface optimization is critical for improving the performance and stability of perovskite solar cells (PSCs) but is restricted by the conventional fabrication approach of sequential layer deposition. While the bottom transport layer is processed with minimum constraints, the narrow thermal and chemical stability window of the halide perovskite (HP) layer severely restricts the choice of top transport layer and its processing conditions. To overcome these limitations, we demonstrate lamination of HPs—where two transport layer-perovskite half-stacks are independently processed and diffusion-bonded at the HP-HP interface—as an alternative fabrication strategy that enables self-encapsulated solar cells. Power conversion efficiencies (PCE) of >21% are realized using cells that incorporate a novel transport layer combination along with dual-interface passivation via self-assembled monolayers, both of which are uniquely enabled by the lamination approach. This is the highest reported PCE for any laminated PSC encapsulated between glass substrates. We further show that this approach expands the processing window beyond traditional fabrication processes and is adaptable for different transport layer compositions. The laminated PSCs retained >75% of their initial PCE after 1000 h of 1-sun illumination at 40 °C in air using an all-inorganic transport layer configuration without additional encapsulation. Furthermore, a laminated 1 cm 2 device maintained a V oc of 1.16 V. Finally, the scalable lamination strategy in this study enables the implementation of new transport layers and interfacial engineering approaches for improving performance and stability.

14 SOLAR ENERGY↗
DOE OSTI2022

Improving the damage tolerance of Si 3 N 4 by forming laminate composites with refractory metals

The objective of this research was to demonstrate that the damage tolerance of Si 3 N 4 could be significantly improved by forming laminate composites with refractory metals, providing materials that undergo graceful failure, rather than the fast-fracture mechanism exhibited by monolithic Si 3 N 4 . A damage tolerant Si 3 N 4 could be used as a ring material in an all-ceramic bearing, decreasing the chance for catastrophic failure if the ring is stressed in tension during operation. The technical approach formed a laminate composite material using alternating Si 3 N 4 -metallic layers, with both outer layers being Si 3 N 4 to take advantage of its greater wear resistance, chemical stability, and thermal stability. The metallic layers are designed to arrest any cracks in the outer layers, thus producing a toughened Si 3 N 4 and avoiding the catastrophic failure behavior exhibited by monolithic ceramics. The laminate composites were fabricated using a combination of tape-casting Si 3 N 4 and metals from slurries, as well as metal foils, followed by hot pressing at 1500°C. The metallic materials employed were chromium, titanium, and tantalum. Analysis confirmed that the interfaces were well formed, and the laminates with chromium and titanium formed intermetallic compounds more readily than the composites with tantalum. The Si 3 N 4 -Ta laminates demonstrated crack deflection and bridging behavior during failure and flexural strength of 800–900 MPa. The hardness and elastic modulus of Si 3 N 4 -Ta laminates measured by nanoindentation were similar to those reported in literature. The hardness across the interface of the Si 3 N 4 -Ta composite varied according to the composition of the interface, which displayed a profile indicative of a diffusion bond.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A Lamination Model for Pressure-Assisted Sintering of Multilayered Porous Structures

This work describes a lamination model for pressure-assisted sintering of thin, multilayered, and porous structures based on the linear viscous constitutive theory of sintering and the classical laminated plate theory of continuum mechanics. A constant out-of-plane normal stress is assumed in the constitutive relation. The lamination relations between the force/moment resultants and the strain/curvature rates are presented. Numerical simulations were performed for a symmetric tri-layer laminate consisting of a 10% gadolinia doped ceria (Ce 0.9 Gd 0.1 O 1.95-δ ) composite structure, where porous layers were adhered to the top and bottom of a denser layer under uniaxially-applied pressures and the sinter forging conditions. The numerical results show that, compared with free sintering, the applied pressure can significantly reduce the sintering time required to achieve given layer thicknesses and porosities. Unlike free sintering, which results in a monotonic decrease of the laminate in-plane dimension, pressure-assisted sintering may produce an in-plane dimension increase or decrease, depending on the applied pressure and sintering time. Finally, the individual layers in the laminate exhibit different stress characteristics under pressure-assisted sintering.

42 ENGINEERING↗
DOE OSTI2016

Electrical characteristics of SrTiO{sub 3}/Al{sub 2}O{sub 3} laminated film capacitors

The electrical characteristics of SrTiO{sub 3}/Al{sub 2}O{sub 3} (160 nm up/90 nm down) laminated film capacitors using the sol-gel process have been investigated. SrTiO{sub 3} is a promising and extensively studied high-K dielectric material, but its leakage current property is poor. SrTiO{sub 3}/Al{sub 2}O{sub 3} laminated films can effectively suppress the demerits of pure SrTiO{sub 3} films under low electric field, but the leakage current value reaches to 0.1 A/cm{sup 2} at higher electric field (>160 MV/m). In this study, a new approach was applied to reduce the leakage current and improve the dielectric strength of SrTiO{sub 3}/Al{sub 2}O{sub 3} laminated films. Compared to laminated films with Au top electrodes, dielectric strength of laminated films with Al top electrodes improves from 205 MV/m to 322 MV/m, simultaneously the leakage current maintains the same order of magnitude (10{sup −4} A/cm{sup 2}) until the breakdown occurs. The above electrical characteristics are attributed to the anodic oxidation reaction in origin, which can repair the defects of laminated films at higher electric field. The anodic oxidation reactions have been confirmed by the corresponding XPS measurement and the cross sectional HRTEM analysis. This work provides a new approach to fabricate dielectrics with high dielectric strength and low leakage current.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS1975

A theory for predicting composite laminate warpage resulting from fabrication

Linear laminate theory is used in conjunction with the moment-curvature relationship to derive equations for predicting end deflections due to warpage without solving the coupled fourth-order partial differential equations of the plate. Using these equations, it is found that a 1 deg error in the orientation angle of one ply is sufficient to produce warpage end deflection equal to two laminate thicknesses in a 10 inch by 10 inch laminate made from 8-ply Mod-I/epoxy. From a sensitivity analysis on the governing parameters, it is found that a 3 deg fiber migration or a void volume ratio of three percent in some plies is sufficient to produce laminate warpage corner deflection equal to several laminate thicknesses. Tabular and graphical data are presented which can be used to identify possible errors contributing to laminate warpage and/or to obtain an a priori assessment when unavoidable errors during fabrication are anticipated.

Chamis, C. C.↗
NASA NTRS1977

Influence of residual stresses on the tensile strength of composite-metal sandwich laminates

The tensile strength of boron-epoxy/aluminum sandwich laminates is discussed relative to the residual thermal stresses generated by curing and bonding at elevated temperatures. It is shown that the sandwich laminates investigated exhibit three dinstinct modes of failure, depending upon the fiber orientation of the composite. Sandwich laminates with moderate to high percentage of 0-deg fibers exhibit early failures initiated by edge effect; laminates with moderate to high percentage of 90-deg fibers fail according to a first-ply failure criterion; laminates with moderate to high percentages of plus or minus 45 deg plies fail at strains equal to or greater than the failure strain of the corresponding all-composite laminate.

Herakovich, C. T.↗
NASA NTRS1979

Effects of low-velocity impact on Gr/Pi compression laminates

The results of low velocity impact tests conducted on a graphite-polyimide laminate are presented. The 48-ply orthotropic laminate tested during this investigation is typical of laminates being proposed for heavily loaded aircraft wing skins. The nature of the damage is described as well as the effect of that damage on the compression strength of the 48-ply orthotropic laminate. The results obtained for the graphite-polyimide laminate are compared to existing results of similar tests conducted on other graphite-epoxy laminates.

Garcia, R.↗
NASA NTRS1980

Three dimensional inelastic finite element analysis of laminated composites

Formulations of the inelastic response of laminated composites to thermal and mechanical loading are used as the basis for development of the computer NALCOM (Nonlinear Analysis of Laminated Composites) computer program which uses a fully three dimensional isoparametric finite element with 24 nodes and 72 degrees of freedom. An incremental solution is performed with nonlinearities introduced as pseudoloads computed for initial strains. Equilibrium iteration may be performed at every step. Elastic and elastic-plastic response of boron/epoxy and graphite/epoxy graphite/epoxy and problems of curing 0/90 sub s Gr/Ep laminates with and without circular holes are analyzed. Mechanical loading of + or - 45sub s Gr/Ep laminates is modeled and symmetry conditions which exist in angle-ply laminates are discussed. Results are compared to experiments and other analytical models when possible. All models are seen to agree reasonably well with experimetnal results for off-axis tensile coupons. The laminate analyses show the three dimensional effects which are present near holes and free corners.

Griffin, O. H., Jr.↗
NASA NTRS1982

Improved damage tolerance of titanium by adhesive lamination

Basic damage tolerance properties of Ti-6A1-4V titanium plate can be improved by laminating thin sheets of titanium with adhesives. Compact tension and center cracked tension specimens made from thick plate, thin sheet, and laminated plate (six plies of thin sheet) were tested. The fracture toughness of the laminated plate was 39 percent higher than the monolithic plate. The laminated plate's through the thickness crack growth rate was about 20 percent less than that of the monolithic plate. The damage tolerance life of the surface cracked laminate was 6 to over 15 times the life of a monolithic specimen. A simple method of predicting crack growth in a crack ply of a laminate is presented.

Johnson, W. S.↗
NASA NTRS1982

The room-temperature shapes of four-layer unsymmetric cross-ply laminates

A geometrically nonlinear extension of classical lamination theory developed by Hyer (1981) for predicting the room-temperature shapes of unsymmetric laminates is reformulated using relaxed restrictions regarding the inplane strains. The inplane residual strains of unsymmetric laminates which have cooled from curing into a cylindrical room-temperature shape are examined numerically. Results show that the residual strains are compressive and practically independent of spatial location on the laminate. In addition, the room temperature shapes of the four-layer unsymmetric cross-ply laminates are predicted, and it is shown that the temperature shapes are a strong function of their size and their stacking arrangement. It is demonstrated that, depending on the parameters selected, the room-temperature shape of a four-layer cross-ply unsymmetric laminate can be a unique saddle shape, a unique cylindrical shape, or a cylindrical shape that can be snapped through to another cylindrical shape.

Hyer, M. W.↗
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.↗