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NASA NTRS1995

Time-dependent deformation of titanium metal matrix composites

A three-dimensional finite element program called VISCOPAC was developed and used to conduct a micromechanics analysis of titanium metal matrix composites. The VISCOPAC program uses a modified Eisenberg-Yen thermo-viscoplastic constitutive model to predict matrix behavior under thermomechanical fatigue loading. The analysis incorporated temperature-dependent elastic properties in the fiber and temperature-dependent viscoplastic properties in the matrix. The material model was described and the necessary material constants were determined experimentally. Fiber-matrix interfacial behavior was analyzed using a discrete fiber-matrix model. The thermal residual stresses due to the fabrication cycle were predicted with a failed interface, The failed interface resulted in lower thermal residual stresses in the matrix and fiber. Stresses due to a uniform transverse load were calculated at two temperatures, room temperature and an elevated temperature of 650 C. At both temperatures, a large stress concentration was calculated when the interface had failed. The results indicate the importance of accuracy accounting for fiber-matrix interface failure and the need for a micromechanics-based analytical technique to understand and predict the behavior of titanium metal matrix composites.

Bigelow, C. A.↗

NASA NTRS1976

Micromechanics of slip bands on a free surface

A micromechanics analysis for the formation and propagation of slip bands on the free surface of a polycrystal under monotonic loading is presented. For the growth of slip bands, the analysis satisfies the conditions of both equilibrium and displacement continuity, as well as the relation between slip and the resolved shear stress throughout the polycrystal. Numerical calculations show how the microstress field causes the concentration of plastic deformation in discrete sliding bands and give results which are in good qualitative agreement with known slip band observations on aluminum single crystals.

Lin, S. R.↗

NASA NTRS1984

Investigation of the relations between neat resin and advanced composite mechanical properties. Volume 1: Results

A detailed evaluation of one untoughened epoxy baseline resin and three toughened epoxy resin systems was performed. The Hercules 3502, 2220-1, and 2220-3, and Ciba-Geigy Fibredux 914 resin systems were supplied in the uncured state by NASA-Langley and cast into thin flat specimens and round dogbone specimens. Tensile and torsional shear measurements were performed at three temperatures and two moisture conditions. Coefficients of thermal expansion and moisture expansion were also measured. Extensive scanning electron microscopic examination of fracture surfaces was performed, to permit the correlation of observed failure modes with the environmental conditions under which the various specimens were tested. A micromechanics analysis was used to predict the unidirectional composite response under the various test conditions, using the neat resin experimental results as the required input data. Mechanical and physical test results, the scanning electron microscope observations, and the analytical predictions were then correlated.

Zimmerman, R. S.↗

NASA NTRS1984

Investigation of the relations between resin and advanced composite mechanical properties. Volume 2: Appendices

One untoughened epoxy baseline resin and three toughened epoxy resin systems were evaluated. The Hercules 3502, 2220-1, and 2220-3, and Ciba-Geigy Fibredux 914 resin systems were supplied in the uncured state by NASA-Langley and cast into thin flat specimens and round dogbone specimens. Tensile and torsional shear measurements were performed at three temperatures and two moisture conditions. Coefficients of thermal expansion and moisture expansion were also measured. Extensive scanning electron microscopic examination of fracture surfaces was performed to permit the correlation of observed failure modes with the environmental conditions under which the various specimens were tested. A micromechanics analysis was used to predict the unidirectional composite response under the various test conditions, incorporating the neat resin experimental results as the required input data. The mechanical and physical test results, the scanning electron microscope observations, and the analytical predictions were then correlated.

Zimmerman, R. S.↗

NASA NTRS1985

Polymer matrix and graphite fiber interface study

Hercules AS4 graphite fiber, unsized, or with EPON 828, PVA, or polysulfone sizing, was combined with three different polymer matrices. These included Hercules 3501-6 epoxy, Hercules 4001 bismaleimide, and Hexcel F155 rubber toughened epoxy. Unidirectional composites in all twelve combinations were fabricated and tested in transverse tension and axial compression. Quasi-isotropic laminates were tested in axial tension and compression, flexure, interlaminar shear, and tensile impact. All tests were conducted at both room temperature, dry and elevated temperature, and wet conditions. Single fiber pullout testing was also performed. Extensive scanning electron microphotographs of fracture surfaces are included, along with photographs of single fiber pullout failures. Analytical/experimental correlations are presented, based on the results of a finite element micromechanics analysis. Correlations between matrix type, fiber sizing, hygrothermal environment, and loading mode are presented. Results indicate that the various composite properties were only moderately influenced by the fiber sizings utilized.

Adams, D. F.↗

NASA NTRS1985

Mechanical properties testing of candidate polymer matrix materials for use in high performance composites

The mechanical properties of four candidate neat resin systems for use in graphite/epoxy composites are characterized. This includes tensile and shear stiffnesses and strengths, coefficients of thermal and moisture expansion, and fracture toughness. Tests are conducted on specimens in the dry state and moisture-saturated, at temperatures of 23C, 82C and 121C. The neat resins tested are Hexcel HX-1504, Narmco 5245-C, American Cyanamid CYCOM 907, and Union Carbide ERX-4901A (MDA). Results are compared with those obtained for four other epoxy resins tested in a prior program, i.e., Hercules 3502, 2220-1, and 2220-3, and Ciba-Geigy Fibredux 914, as well as with available Hercules 3501-6 data. Scanning electron microscopic examination of fracture surfaces is performed to permit the correlation of observed failure modes with the environmental test conditions. A finite element micromechanics analysis is used to predict unidirectional composite response under various test conditions, using the measured neat resin properties as input data.

Zimmerman, R. S.↗

NASA NTRS1991

A constitutive relation for the viscous flow of an oriented fiber assembly

A constitutive relation for an equivalent, homogeneous fluid is developed for the anisotropic viscous flow of an oriented assembly of discontinuous fibers suspended in a viscous fluid. The anisotropic viscous compliance matrix can be expressed in terms of three constants by assuming the equivalent fluid to be incompressible and the microstructure to have axial symmetry (transversely isotropic). By means of a micromechanics analysis, the three terms of the constitutive relation are expressed in terms of the viscosity of the matrix fluid, the fiber aspect ratio, and the fiber volume fraction. A comparison of the viscosity terms reveals that the elongational viscosity in the fiber direction varies as the square of the fiber aspect ratio and a complex function of the fiber volume fraction. Furthermore, the ratio of the axial elongational viscosity to the transverse elongational viscosity and both axial and transverse shear viscosities was shown to be 10 exp 4 - 10 exp 6 for fiber aspect ratio of 100-1000, except at extreme values of the fiber volume fraction.

Pipes, R. B.↗

NASA NTRS1992

Thermal residual stresses in silicon-carbide/titanium (0/90) laminate

The current work formulated a micromechanical analysis of a cross-ply laminate and calculated the thermal residual stress in a very thick (0/90)(sub 2n) silicon-carbide/titanium laminate. Results were also shown for a unidirectional laminate of the same material. Discrete fiber-matrix models assuming a rectangular array of fibers with a fiber volume fraction of 32.5 percent and a three-dimensional, finite-element analysis were used. Significant differences in the trends and magnitudes for the fiber, matrix, and interface stresses were calculated for unidirectional and (0/90) models. Larger hoop stresses calculated for the (0/90) model indicate that it may be more susceptible to radial cracking when subjected to mechanical loading than the unidirectional model. The axial stresses in the matrix were calculated to be slightly larger for the (0/90) model. The compressive axial stresses in the fiber were significantly larger in the (0/90) model. The presence of the cross-ply in the (0/90) model reduced the constraint on the fiber, producing radial interface stresses that were less compressive, which could lead to earlier failure of the fiber-matrix interface.

Bigelow, C. A.↗

NASA NTRS1992

Micromechanics of metal matrix composites using the Generalized Method of Cells model (GMC) user's guide

A user's guide for the program gmc.f is presented. The program is based on the generalized method of cells model (GMC) which is capable via a micromechanical analysis, of predicting the overall, inelastic behavior of unidirectional, multi-phase composites from the knowledge of the properties of the viscoplastic constituents. In particular, the program is sufficiently general to predict the response of unidirectional composites having variable fiber shapes and arrays.

Aboudi, Jacob↗

NASA NTRS1993

Prediction of stable tearing of 2024-T3 aluminum alloy using the crack-tip opening angle approach

In this study, the crack-tip opening angle (CTOA) approach was incorporated into a damage growth finite element program, MADGIC (Micromechanics Analysis and Damage Growth in Composites), and was used to predict stable tearing in a middle-crack tension 2024-T3 aluminum alloy specimen. The MADGIC code is a displacement based finite element program implemented with an incremental elastic-plastic algorithm used to model elastic-plastic behavior and a nodal splitting and nodal force relaxation algorithm used to generate crack surfaces. Predictions of the applied stress as a function of crack extension and applied stress as a function of load-line displacement were in good agreement with experiments and with similar predictions made using an existing finite element program, ZIP2D. In addition, path integrals, namely, the J-integral and T*-integral, were also evaluated and compared with the CTOA approach. There appears to be a weak relationship between the CTOA and the T*-integral evaluated on a specific integration path during crack extension beyond maximum applied stress. This study further verifies that the CTOA can be used as an effective elastic-plastic fracture mechanics parameter to predict crack growth.

Bakuckas, J. G., Jr.↗

NASA NTRS1993

Determination of fiber-matrix interface failure parameters from off-axis tests

Critical fiber-matrix (FM) interface strength parameters were determined using a micromechanics-based approach together with failure data from off-axis tension (OAT) tests. The ply stresses at failure for a range of off-axis angles were used as input to a micromechanics analysis that was performed using the personal computer-based MICSTRAN code. FM interface stresses at the failure loads were calculated for both the square and the diamond array models. A simple procedure was developed to determine which array had the more severe FM interface stresses and the location of these critical stresses on the interface. For the cases analyzed, critical FM interface stresses were found to occur with the square array model and were located at a point where adjacent fibers were closest together. The critical FM interface stresses were used together with the Tsai-Wu failure theory to determine a failure criterion for the FM interface. This criterion was then used to predict the onset of ply cracking in angle-ply laminates for a range of laminate angles. Predictions for the onset of ply cracking in angle-ply laminates agreed with the test data trends.

Naik, Rajiv A.↗

NASA NTRS1994

Prediction of thermal and mechanical stress-strain responses of TMC's subjected to complex TMF histories

This paper presents an experimental and analytical evaluation of cross-plied laminates of Ti-15V-3Cr-3Al-3Sn (Ti-15-3) matrix reinforced with continuous silicon-carbide fibers (SCS-6) subjected to a complex TMF loading profile. Thermomechanical fatigue test techniques were developed to conduct a simulation of a generic hypersonic flight profile. A micromechanical analysis was used. The analysis predicts the stress-strain response of the laminate and of the constituents in each ply during thermal and mechanical cycling by using only constituent properties as input. The fiber was modeled as elastic with transverse orthotropic and temperature-dependent properties. The matrix was modeled using a thermoviscoplastic constitutive relation. The fiber transverse modulus was reduced in the analysis to simulate the fiber-matrix interface failures. Excellent correlation was found between measured and predicted laminate stress-strain response due to generic hypersonic flight profile when fiber debonding was modeled.

Johnson, W. S.↗

NASA NTRS2000

A New Local Failure Model with Application to the Longitudinal Tensile Behavior of Continuously Reinforced Titanium Composites

A new model for local fiber failures in composite materials loaded longitudinally is presented. In developing the model, the goal was to account for the effects of fiber breakage on the global response of a composite in a relatively simple and efficient manner. Towards this end, the model includes the important feature of local stress unloading, even as global loading of the composite continues. The model has been incorporated into NASA Glenn's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) and was employed to simulate the longitudinal tensile deformation and failure behavior of several silicon carbide fiber/titanium matrix (SiC/Ti) composites. The model is shown to be quite realistic and capable of accurate predictions for various temperatures, fiber volume fractions, and fiber diameters. Further- more, the new model compares favorably to Curtin's (1993) effective fiber breakage model, which has also been incorporated into MAC/GMC.

Bednarcyk, Brett A.↗

NASA NTRS2000

Modeling Woven Polymer Matrix Composites with MAC/GMC

NASA's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) is used to predict the elastic properties of plain weave polymer matrix composites (PMCs). The traditional one step three-dimensional homogertization procedure that has been used in conjunction with MAC/GMC for modeling woven composites in the past is inaccurate due to the lack of shear coupling inherent to the model. However, by performing a two step homogenization procedure in which the woven composite repeating unit cell is homogenized independently in the through-thickness direction prior to homogenization in the plane of the weave, MAC/GMC can now accurately model woven PMCs. This two step procedure is outlined and implemented, and predictions are compared with results from the traditional one step approach and other models and experiments from the literature. Full coupling of this two step technique with MAC/ GMC will result in a widely applicable, efficient, and accurate tool for the design and analysis of woven composite materials and structures.

Bednarcyk, Brett A.↗

NASA NTRS2004

Time-Temperature Dependent Response of Filament Wound Composites for Flywheel Rotors

Flywheel energy storage offers an attractive alternative to battery systems used in space applications such as the International Space Station. Rotor designs capable of high specific energies benefit from the load carrying capacity of hoop wound carbon fibers but their long-term durability may be limited by time-temperature dependent radial deformations. This was investigated for the carbon/epoxy rotor material, IM7/8552. Coupon specimens were sectioned from filament wound panels. These were tested in compression and tension at room temperature (RT), 95 and 135 C for strain rates from 5x10(exp -6) per second to 5x10(exp -3) per second. Time, temperature and load sign dependent effects were significant transverse to the fiber. At -0.5 percent strain for 72 hr, compressive stresses relaxed 16.4 percent at 135 C and 13 percent at 95 C. Tensile stresses relaxed only 7 percent in 72 hr at 135 C for 0.5 percent strain. Using linear hereditary material response and Boltzmann s principle of superposition to describe this behavior is problematic if not intractable. Micromechanics analysis including the effects of processing residual stresses is needed to resolve the paradoxes. Uniaxial compressive stress relaxation data may be used to bound the loss of radial pre-load stresses in flywheel rotors.

Thesken, John C.↗

NASA NTRS2004

Cross-Linked Nanotube Materials with Variable Stiffness Tethers

The constitutive properties of a cross-linked single-walled carbon nanotube material are predicted with a multi-scale model. The material is modeled as a transversely isotropic solid using concepts from equivalent-continuum modeling. The elastic constants are determined using molecular dynamics simulation. Some parameters of the molecular force field are determined specifically for the cross-linker from ab initio calculations. A demonstration of how the cross-linked nanotubes may affect the properties of a nanotube/polyimide composite is included using a micromechanical analysis.

Frankland, Sarah-Jane V.↗

NASA NTRS2005

Multi-Scale Sizing of Lightweight Multifunctional Spacecraft Structural Components

This document is the final report for the project entitled, "Multi-Scale Sizing of Lightweight Multifunctional Spacecraft Structural Components," funded under the NRA entitled "Cross-Enterprise Technology Development Program" issued by the NASA Office of Space Science in 2000. The project was funded in 2001, and spanned a four year period from March, 2001 to February, 2005. Through enhancements to and synthesis of unique, state of the art structural mechanics and micromechanics analysis software, a new multi-scale tool has been developed that enables design, analysis, and sizing of advance lightweight composite and smart materials and structures from the full vehicle, to the stiffened structure, to the micro (fiber and matrix) scales. The new software tool has broad, cross-cutting value to current and future NASA missions that will rely on advanced composite and smart materials and structures.

Bednarcyk, Brett A.↗

NASA NTRS2001

Local Debonding and Fiber Breakage in Composite Materials Modeled Accurately

A prerequisite for full utilization of composite materials in aerospace components is accurate design and life prediction tools that enable the assessment of component performance and reliability. Such tools assist both structural analysts, who design and optimize structures composed of composite materials, and materials scientists who design and optimize the composite materials themselves. NASA Glenn Research Center's Micromechanics Analysis Code with Generalized Method of Cells (MAC/GMC) software package (http://www.grc.nasa.gov/WWW/LPB/mac) addresses this need for composite design and life prediction tools by providing a widely applicable and accurate approach to modeling composite materials. Furthermore, MAC/GMC serves as a platform for incorporating new local models and capabilities that are under development at NASA, thus enabling these new capabilities to progress rapidly to a stage in which they can be employed by the code's end users.

Bednarcyk, Brett A.↗