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NASA NTRS2013

Simulation of Detecting Damage in Composite Stiffened Panel Using Lamb Waves

Lamb wave damage detection in a composite stiffened panel is simulated by performing explicit transient dynamic finite element analyses and using signal imaging techniques. This virtual test process does not need to use real structures, actuators/sensors, or laboratory equipment. Quasi-isotropic laminates are used for the stiffened panels. Two types of damage are studied. One type is a damage in the skin bay and the other type is a debond between the stiffener flange and the skin. Innovative approaches for identifying the damage location and imaging the damage were developed. The damage location is identified by finding the intersection of the damage locus and the path of the time reversal wave packet re-emitted from the sensor nodes. The damage locus is a circle that envelops the potential damage locations. Its center is at the actuator location and its radius is computed by multiplying the group velocity by the time of flight to damage. To create a damage image for estimating the size of damage, a group of nodes in the neighborhood of the damage location is identified for applying an image condition. The image condition, computed at a finite element node, is the zero-lag cross-correlation (ZLCC) of the time-reversed incident wave signal and the time reversal wave signal from the sensor nodes. This damage imaging process is computationally efficient since only the ZLCC values of a small amount of nodes in the neighborhood of the identified damage location are computed instead of those of the full model.

Wang, John T.↗

NASA NTRS2024

Characterization of Low-Velocity Impact Damage in Toughened Non-Crimp Fabric Laminates

The damage response of resin-infused composites was investigated using quasi-static indentation (QSI) and instrumented drop-weight impact testing. The test specimens were composed of six layers of non-crimp fabrics where each layer contained +45°, 90°, −45°, and 0° plies. The goals of the testing were to identify damage responses that may differ from traditional thermoset materials and provide damage characterization data to evaluate current damage prediction analyses and aid improvements to current damage models. The damage was characterized using X-ray computed tomography (CT) and ultrasonic testing (UT). Incremental QSI loading was used on a single specimen to investigate damage growth in nine steps at progressively higher loads. Realtime acoustic emission data were used to determine the unloading points. Unlike typical thermoset composites, the force-displacement was smooth and showed no obvious indications of damage. The primary damage consisted of large lines of fiber fracture on the plies near the impact surface and delaminations through the thickness. Nine specimens were impacted at nominal impact energies of 25 ft-lbs, 30 ft-lbs, and 35 ft-lbs. The force histories at each energy followed nearly identical paths. Again, no obvious signs of damage were observed in any of the force histories. The general damage response in the dynamic tests was similar to the QSI-loaded specimens. However, repeat specimens impacted with a given impact energy showed variations in the damage. Some characteristics of the damage response were different than those typically observed in thermoset composites and will need to be evaluated using current analysis methods.

Composite Materials↗

NASA NTRSDate not supplied

Characterization of Low-Velocity Impact Damage in Toughened Non-Crimp Fabric Laminates

Composite Materials↗

DOE OSTI2022

Tree crown damage and its effects on forest carbon cycling in a tropical forest

Abstract Crown damage can account for over 23% of canopy biomass turnover in tropical forests and is a strong predictor of tree mortality; yet, it is not typically represented in vegetation models. We incorporate crown damage into the Functionally Assembled Terrestrial Ecosystem Simulator (FATES), to evaluate how lags between damage and tree recovery or death alter demographic rates and patterns of carbon turnover. We represent crown damage as a reduction in a tree's crown area and leaf and branch biomass, and allow associated variation in the ratio of aboveground to belowground plant tissue. We compare simulations with crown damage to simulations with equivalent instant increases in mortality and benchmark results against data from Barro Colorado Island (BCI), Panama. In FATES, crown damage causes decreases in growth rates that match observations from BCI. Crown damage leads to increases in carbon starvation mortality in FATES, but only in configurations with high root respiration and decreases in carbon storage following damage. Crown damage also alters competitive dynamics, as plant functional types that can recover from crown damage outcompete those that cannot. This is a first exploration of the trade‐off between the additional complexity of the novel crown damage module and improved predictive capabilities. At BCI, a tropical forest that does not experience high levels of disturbance, both the crown damage simulations and simulations with equivalent increases in mortality does a reasonable job of capturing observations. The crown damage module provides functionality for exploring dynamics in forests with more extreme disturbances such as cyclones and for capturing the synergistic effects of disturbances that overlap in space and time.

Needham, Jessica F.↗

NASA NTRS1990

Relevance of impacter shape to nonvisible damage and residual tensile strength of a thick graphite/epoxy laminate

A study was made to determine the relevance of impacter shape to nonvisible damage and tensile residual strength of a 36 mm (1.4 in.) thick graphite/epoxy motor case. The shapes of the impacters were as follows: 12.7 mm (0.5 in.) and 25.4 mm (1.0 in.) diameter hemispheres, a sharp corner, and a 6.3 mm (0.25 in.) diameter bolt-like rod. The investigation revealed that damage initiated when the contact pressure exceeded a critical level. However, the damage was not visible on the surface until an even higher pressure was exceeded. The damage on the surface consisted of a crater shaped like the impacter, and the damage below the surface consisted of broken fibers. The impact energy to initiate damage or cause visible damage on the surface increased approximately with impacter diameter to the third power. The reduction in strength for nonvisible damage increased with increasing diameter, 9 and 30 percent for the 12.7 mm (0.5 in.) and 25.4 mm (1.0 in.) diameter hemispheres, respectively. The corner impacter made visible damage on the surface for even the smallest impact energy. The rod impacter acted like a punch and sliced through the composite. Even so, the critical level of pressure to initiate damage was the same for the rod and hemispherical impacters. Factors of safety for nonvisible damage increased with increasing kinetic energy of impact. The effects of impacter shape on impact force, damage size, damage visibility, and residual tensile strength were predicted quite well assuming Hertzian contact and using maximum stress criteria and a surface crack analysis.

Poe, C. C., Jr.↗

NASA NTRS2008

STS-118 Radiator Impact Damage

During the August 2007 STS-118 mission to the International Space Station, a micro-meteoroid or orbital debris (MMOD) particle impacted and completely penetrated one of shuttle Endeavour s radiator panels and the underlying thermal control system (TCS) blanket, leaving deposits on (but no damage to) the payload bay door. While it is not unusual for shuttle orbiters to be impacted by small MMOD particles, the damage from this impact is larger than any previously seen on the shuttle radiator panels. A close-up photograph of the radiator impact entry hole is shown in Figure 1, and the location of the impact on Endeavour s left-side aft-most radiator panel is shown in Figure 2. The aft radiator panel is 0.5-inches thick and consists of 0.011 inch thick aluminum facesheets on the front and back of an aluminum honeycomb core. The front facesheet is additionally covered by a 0.005 inch thick layer of silver-Teflon thermal tape. The entry hole in the silver-Teflon tape measured 8.1 mm by 6.4 mm (0.32 inches by 0.25 inches). The entry hole in the outer facesheet measured 7.4 mm by 5.3 mm (0.29 inches by 0.21 inches) (0.23 inches). The impactor also perforated an existing 0.012 inch doubler that had been bonded over the facesheet to repair previous impact damage (an example that lightning can strike the same place twice, even for MMOD impact). The peeled-back edge around the entry hole, or lip , is a characteristic of many hypervelocity impacts. High velocity impact with the front facesheet fragmented the impacting particle and caused it to spread out into a debris cloud. The debris cloud caused considerable damage to the internal honeycomb core with 23 honeycomb cells over a region of 28 mm by 26 mm (1.1 inches by 1.0 inches) having either been completely destroyed or partially damaged. Figure 3 is a view of the exit hole in the rear facesheet, and partially shows the extent of the honeycomb core damage and clearly shows the jagged petaled exit hole through the backside facesheet. The rear facesheet exit hole damage including cracks in the facesheet measures 14 mm by 14 mm (0.55 inches by 0.55 inches). The remnants of the impacting particle and radiator panel material blown through the rear facesheet hole also created two penetrations in the TCS blanket 115 mm (4.5 inches) behind the rear facesheet. Figure 4 shows these two impacts, which are located 75 mm (3 inches) apart. Some deposits of material were found on the payload bay door beneath the TCS blanket, but no additional damage occurred to the door. Figure 5 illustrates the relationship of the facesheet entry hole to the TCS blanket damage, which may indicate the direction of the impacting particle. The image on the left side of Figure 5 shows an overhead view of the damaged radiator after the facesheet holes were cored out of the panel. The entry hole location and the two underlying TCS blanket damage sites are annotated on the image. Section A-A, running through the entry hole and TCS blanket damage locations, describes a 25 angle from the longitudinal axis of the shuttle. The 2nd impact angle can be seen in section A-A on the right side of Figure 5. An average 17 angle of impact to the surface normal was derived by measuring the angles of the two damage sites in TCS blanket to the entry hole.

Lear, Dana M.↗

NASA NTRS2017

Damage Simulation in Composite Materials: Why It Matters and What Is Happening Currently at NASA in This Area

Use of lightweight composite materials in space and aircraft structure designs is often challenging due to high costs associated with structural certification. Of primary concern in the use of composite structures is durability and damage tolerance. This concern is due to the inherent susceptibility of composite materials to both fabrication and service induced flaws. Due to a lack of general industry accepted analysis tools applicable to composites damage simulation, a certification procedure relies almost entirely on testing. It is this reliance on testing, especially compared to structures comprised of legacy metallic materials where damage simulation tools are available, that can drive costs for using composite materials in aerospace structures. The observation that use of composites can be expensive due to testing requirements is not new and as such, research on analysis tools for simulating damage in composite structures has been occurring for several decades. A convenient approach many researchers/model-developers in this area have taken is to select a specific problem relevant to aerospace structural certification and develop a model that is accurate within that scope. Some examples are open hole tension tests, compression after impact tests, low-velocity impact, damage tolerance of an embedded flaw, and fatigue crack growth to name a few. Based on the premise that running analyses is cheaper than running tests, one motivation that many researchers in this area have is that if generally applicable and reliable damage simulation tools were available the dependence on certification testing could be lessened thereby reducing overall design cost. It is generally accepted that simulation tools if applied in this manner would still need to be thoroughly validated and that composite testing will never be completely replaced by analysis. Research and development is currently occurring at NASA to create numerical damage simulation tools applicable to damage in composites. The Advanced Composites Project (ACP) at NASA Langley has supported the development of composites damage simulation tools in a consortium of aerospace companies with a goal of reducing the certification time of a commercial aircraft by 30%. And while the scope of ACP does not include spacecraft, much of the methodology and simulation capabilities can apply to spacecraft certification in the Space Launch System and Orion programs as well. Some specific applications of composite damage simulation models in a certification program are (1) evaluation of damage during service when maintenance may be difficult or impossible, (2) a tool for early design iterations, (3) gaining insight into a particular damage process and applying this insight towards a test coupon or structural design, and (4) analysis of damage scenarios that are difficult or impossible to recreate in a test. As analysis capabilities improve, these applications and more will become realized resulting in a reduction in cost for use of composites in aerospace vehicles. NASA is engaged in this process from both research and application perspectives. In addition to the background information discussed previously, this presentation covers a look at recent research at NASA in this area and some current/potential applications in the Orion program.

McElroy, Mack↗

DOE OSTI2022

Quantifying the reduction in cavitation-induced erosion damage in the Spallation Neutron Source mercury target by means of small-bubble gas injection

Here, a model developed to represent the progress of erosion damage in liquid-metal spallation target vessels was modified to incorporate the effect of gas injection on the erosion rate. The liquid mercury target system for the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory now operates with helium gas injection to reduce target vessel fatigue stress and cavitation-induced erosion damage. Erosion damage is a primary degradation phenomenon affecting the service life of SNS target vessels, and cavitation mitigation techniques, such as small-bubble gas injection, have been implemented to reduce damage and extend target lifetimes. Erosion depths in samples removed from SNS targets after operation were measured using laser line scanning. These measurements confirmed that gas injection reduced erosion damage. However, quantifying the damage reduction due to gas injection was complicated by variations in lifetime, power, and gas injection rates between different targets. In this study, the operating power and gas injection rate of targets were incorporated into an erosion damage prediction model to quantify their effects on erosion damage reduction. Values of a power scaling factor, β, were calculated by comparing modeled with measured erosion damage. These values indicate that the use of gas injection at the SNS reduced damage to a level equivalent to operating targets without gas injection at 35–47% of the actual beam power. To account for the gas injection effect on the cavitation damage, a simple exponential form based on analysis of the scaling factor β was developed to incorporate the gas rate history with a scaling factor γ in the erosion damage modeling.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Timing and extent of crop damage by wild pigs (Sus scrofa Linnaeus) to corn and peanut fields

The global expansion of wild pigs over the last few decades has resulted in an increase in extent and distribution of damages to crops, placing a growing strain on agricultural producers and land managers. Despite the extent of wild pig damage to agriculture, there is little data regarding timing and spatial variability of damage to corn (Zea mays Linnaeus) and we found no data regarding the effect of these factors on peanuts (Arachis hypogaea Linnaeus). Our objective was to determine the timing and extent of wild pig damage to corn and peanut fields, as well as the extent to which local habitat attributes are useful predictors of damage to these crops. During 2017–2018 we performed ground-based surveys throughout the growing season for 29 corn and 41 peanut fields in South Carolina, USA to determine the most important growth stages for wild pig depredation in both crops. Damage to corn peaked shortly after planting during the seedling stage, fell to nearly zero during V4–V6 stages, and resumed during the silk and mature stages. Peanut damage was almost exclusively limited to the seedling stage. Landscape models for both crops identified the extent of forested and wetland areas surrounding crop fields as the most important attributes positively associated with wild pig damage, while the amount of adjacent agricultural area and paved roads were associated negatively. The number of wild pigs identified by remote cameras also was an important indicator of the extent of damage to peanut fields. Results suggest management efforts to limit crop depredation by wild pigs should be targeted shortly prior to planting. Further, because damage was positively associated with the availability of wetland and forest habitats, our results suggest agricultural damage by wild pigs may be most severe near areas of preferred native habitats.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2018

A New Standard DNA Damage (SDD) Data Format

Our understanding of radiation-induced cellular damage has greatly improved over the past few decades. Despite this progress, there are still many obstacles to fully understand how radiation interacts with biologically relevant cellular components, such as DNA, to cause observable end points such as cell killing. Damage in DNA is identified as a major route of cell killing. One hurdle when modeling biological effects is the difficulty in directly comparing results generated by members of different research groups. Multiple Monte Carlo codes have been developed to simulate damage induction at the DNA scale, while at the same time various groups have developed models that describe DNA repair processes with varying levels of detail. These repair models are intrinsically linked to the damage model employed in their development, making it difficult to disentangle systematic effects in either part of the modeling chain. These modeling chains typically consist of track-structure Monte Carlo simulations of the physical interactions creating direct damages to DNA, followed by simulations of the production and initial reactions of chemical species causing so-called “indirect” damages. After the induction of DNA damage, DNA repair models combine the simulated damage patterns with biological models to determine the biological consequences of the damage. To date, the effect of the environment, such as molecular oxygen (normoxic vs. hypoxic), has been poorly considered. We propose a new standard DNA damage (SDD) data format to unify the interface between the simulation of damage induction in DNA and the biological modeling of DNA repair processes, and introduce the effect of the environment (molecular oxygen or other compounds) as a flexible parameter. Such a standard greatly facilitates intermodel comparisons, providing an ideal environment to tease out model assumptions and identify persistent, underlying mechanisms. Through inter-model comparisons, this unified standard has the potential to significantly advance our understanding of the underlying mechanisms of radiation-induced DNA damage and the resulting observable biological effects when radiation parameters and/or environmental conditions change.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗

NASA NTRS1998

A New Approach to Overcoming Spatial Aliasing in Structural Damage Detection

Aircraft, reusable launch vehicles,unmanned aircraft, and other advanced structures are being built using lightweight composite materials/metals with design safety factors as low as 1.25. These advanced structures operate in uncertain and severe environments and are susceptible to damage such as delamination, fiber/matrix damage, hydrothermal strain in composite materials, and fatigue and cracking in metals. To ensure human safety and load-bearing integrity these structures must be inspected to detect and locate often invisible damage and faults before they become catastrophic. Conventional methods of non-destructive evaluation sometimes miss significant damage and are time consuming and expensive to perform. In contrast, vibrometry or vibration signature techniques are a global method of structural integrity monitoring that potentially can efficiently detect damage on large structures, including damage that is away from sensor locations, and in the interior of structures. However, a barrier problem in damage detection using vibration measurements is the need to measure the vibration response at a large number of points on the structure. Typically, model reduction or expansion procedures such as Guyan reduction or dynamic expansion are attempted to overcome the problem of insufficient measurements or spatial aliasing. These approaches depend on using information from the healthy model, and thus put error into the reduction used to represent the damaged structure. In this paper, a Frequency Response Function technique is used to detect damage to a fixed-free beam. The technique uses measured frequency response functions from the healthy structure as reference data, and then monitors vibration measurements during the life of the structure to detect damage. In an analytical simulation using a finite-element model of a beam, damage was located using only sparse measurements because the technique uses both rotation and translation measurements from the damaged structure.

Schulz, Mark J.↗

NASA NTRS2007

The Effect of Delamination on Damage Path and Failure Load Prediction for Notched Composite Laminates

The influence of delamination on the progressing damage path and initial failure load in composite laminates is investigated. Results are presented from a numerical and an experimental study of center-notched tensile-loaded coupons. The numerical study includes two approaches. The first approach considers only intralaminar (fiber breakage and matrix cracking) damage modes in calculating the progression of the damage path. In the second approach, the model is extended to consider the effect of interlaminar (delamination) damage modes in addition to the intralaminar damage modes. The intralaminar damage is modeled using progressive damage analysis (PDA) methodology implemented with the VUMAT subroutine in the ABAQUS finite element code. The interlaminar damage mode has been simulated using cohesive elements in ABAQUS. In the experimental study, 2-3 specimens each of two different stacking sequences of center-notched laminates are tensile loaded. The numerical results from the two different modeling approaches are compared with each other and the experimentally observed results for both laminate types. The comparisons reveal that the second modeling approach, where the delamination damage mode is included together with the intralaminar damage modes, better simulates the experimentally observed damage modes and damage paths, which were characterized by splitting failures perpendicular to the notch tips in one or more layers. Additionally, the inclusion of the delamination mode resulted in a better prediction of the loads at which the failure took place, which were higher than those predicted by the first modeling approach which did not include delaminations.

Satyanarayana, Arunkumar↗

NASA NTRS2012

Use of Remote Sensing Data to Enhance NWS Storm Damage Toolkit

In the wake of a natural disaster such as a tornado, the National Weather Service (NWS) is required to provide a very detailed and timely storm damage assessment to local, state and federal homeland security officials. The Post ]Storm Data Acquisition (PSDA) procedure involves the acquisition and assembly of highly perishable data necessary for accurate post ]event analysis and potential integration into a geographic information system (GIS) available to its end users and associated decision makers. Information gained from the process also enables the NWS to increase its knowledge of extreme events, learn how to better use existing equipment, improve NWS warning programs, and provide accurate storm intensity and damage information to the news media and academia. To help collect and manage all of this information, forecasters in NWS Southern Region are currently developing a Storm Damage Assessment Toolkit (SDAT), which incorporates GIS ]capable phones and laptops into the PSDA process by tagging damage photography, location, and storm damage details with GPS coordinates for aggregation within the GIS database. However, this tool alone does not fully integrate radar and ground based storm damage reports nor does it help to identify undetected storm damage regions. In many cases, information on storm damage location (beginning and ending points, swath width, etc.) from ground surveys is incomplete or difficult to obtain. Geographic factors (terrain and limited roads in rural areas), manpower limitations, and other logistical constraints often prevent the gathering of a comprehensive picture of tornado or hail damage, and may allow damage regions to go undetected. Molthan et al. (2011) have shown that high resolution satellite data can provide additional valuable information on storm damage tracks to augment this database. This paper presents initial development to integrate satellitederived damage track information into the SDAT for near real ]time use by forecasters and decision makers.

Jedlove, Gary J.↗

NASA NTRS2013

Damage Detection Response Characteristics of Open Circuit Resonant (SansEC) Sensors

The capability to assess the current or future state of the health of an aircraft to improve safety, availability, and reliability while reducing maintenance costs has been a continuous goal for decades. Many companies, commercial entities, and academic institutions have become interested in Integrated Vehicle Health Management (IVHM) and a growing effort of research into "smart" vehicle sensing systems has emerged. Methods to detect damage to aircraft materials and structures have historically relied on visual inspection during pre-flight or post-flight operations by flight and ground crews. More quantitative non-destructive investigations with various instruments and sensors have traditionally been performed when the aircraft is out of operational service during major scheduled maintenance. Through the use of reliable sensors coupled with data monitoring, data mining, and data analysis techniques, the health state of a vehicle can be detected in-situ. NASA Langley Research Center (LaRC) is developing a composite aircraft skin damage detection method and system based on open circuit SansEC (Sans Electric Connection) sensor technology. Composite materials are increasingly used in modern aircraft for reducing weight, improving fuel efficiency, and enhancing the overall design, performance, and manufacturability of airborne vehicles. Materials such as fiberglass reinforced composites (FRC) and carbon-fiber-reinforced polymers (CFRP) are being used to great advantage in airframes, wings, engine nacelles, turbine blades, fairings, fuselage structures, empennage structures, control surfaces and aircraft skins. SansEC sensor technology is a new technical framework for designing, powering, and interrogating sensors to detect various types of damage in composite materials. The source cause of the in-service damage (lightning strike, impact damage, material fatigue, etc.) to the aircraft composite is not relevant. The sensor will detect damage independent of the cause. Damage in composite material is generally associated with a localized change in material permittivity and/or conductivity. These changes are sensed using SansEC. The unique electrical signatures (amplitude, frequency, bandwidth, and phase) are used for damage detection and diagnosis. An operational system and method would incorporate a SansEC sensor array on select areas of the aircraft exterior surfaces to form a "Smart skin" sensing surface. In this paper a new method and system for aircraft in-situ damage detection and diagnosis is presented. Experimental test results on seeded fault damage coupons and computational modeling simulation results are presented. NASA LaRC has demonstrated with individual sensors that SansEC sensors can be effectively used for in-situ composite damage detection of delamination, voids, fractures, and rips. Keywords: Damage Detection, Composites, Integrated Vehicle Health Monitoring (IVHM), Aviation Safety, SansEC Sensors

Dudley, Kenneth L.↗

NASA NTRS2015

Development of a Near Real-Time Hail Damage Swath Identification Algorithm for Vegetation

Every year in the Midwest and Great Plains, widespread greenness forms in conjunction with the latter part of the spring-summer growing season. This prevalent greenness forms as a result of the high concentration of agricultural areas having their crops reach their maturity before the fall harvest. This time of year also coincides with an enhanced hail frequency for the Great Plains (Cintineo et al. 2012). These severe thunderstorms can bring damaging winds and large hail that can result in damage to the surface vegetation. The spatial extent of the damage can relatively small concentrated area or be a vast swath of damage that is visible from space. These large areas of damage have been well documented over the years. In the late 1960s aerial photography was used to evaluate crop damage caused by hail. As satellite remote sensing technology has evolved, the identification of these hail damage streaks has increased. Satellites have made it possible to view these streaks in additional spectrums. Parker et al. (2005) documented two streaks using the Moderate Resolution Imaging Spectroradiometer (MODIS) that occurred in South Dakota. He noted the potential impact that these streaks had on the surface temperature and associated surface fluxes that are impacted by a change in temperature. Gallo et al. (2012) examined at the correlation between radar signatures and ground observations from storms that produced a hail damage swath in Central Iowa also using MODIS. Finally, Molthan et al. (2013) identified hail damage streaks through MODIS, Landsat-7, and SPOT observations of different resolutions for the development of a potential near-real time applications. The manual analysis of hail damage streaks in satellite imagery is both tedious and time consuming, and may be inconsistent from event to event. This study focuses on development of an objective and automatic algorithm to detect these areas of damage in a more efficient and timely manner. This study utilizes the MODIS sensor aboard the NASA Aqua satellite. Aqua was chosen due to an afternoon orbit over the United States when land surface temperatures are relatively warm and improve the contrast between damaged and undamaged areas. This orbit is also similar to the orbit of the Suomi-National Polar-orbiting Partnership (NPP) satellite. The Suomi NPP satellite hosts the Visible Infrared Imaging Radiometer Suite (VIIRS) instrument, which is the next generation of a MODIS-like sensor in polar orbit.

MODIS VIIRS↗

NASA NTRS2017

Structural Health Management of Damaged Aircraft Structures Using the Digital Twin Concept

The development of multidisciplinary integrated Structural Health Management (SHM) tools will enable accurate detection, and prognosis of damaged aircraft under normal and adverse conditions during flight. As part of the digital twin concept, methodologies are developed by using integrated multiphysics models, sensor information and input data from an in-service vehicle to mirror and predict the life of its corresponding physical twin. SHM tools are necessary for both damage diagnostics and prognostics for continued safe operation of damaged aircraft structures. The adverse conditions include loss of control caused by environmental factors, actuator and sensor faults or failures, and structural damage conditions. A major concern in these structures is the growth of undetected damage/cracks due to fatigue and low velocity foreign object impact that can reach a critical size during flight, resulting in loss of control of the aircraft. To avoid unstable, catastrophic propagation of damage during a flight, load levels must be maintained that are below a reduced load-carrying capacity for continued safe operation of an aircraft. Hence, a capability is needed for accurate real-time predictions of damage size and safe load carrying capacity for structures with complex damage configurations. In the present work, a procedure is developed that uses guided wave responses to interrogate damage. As the guided wave interacts with damage, the signal attenuates in some directions and reflects in others. This results in a difference in signal magnitude as well as phase shifts between signal responses for damaged and undamaged structures. Accurate estimation of damage size, location, and orientation is made by evaluating the cumulative signal responses at various pre-selected sensor locations using a genetic algorithm (GA) based optimization procedure. The damage size, location, and orientation is obtained by minimizing the difference between the reference responses and the responses obtained by wave propagation finite element analysis of different representative cracks, geometries, and sizes.

Seshadri, Banavara R.↗

DOE OSTI2024

Broadband 920-nm mirror thin film damage competition

The 2023 Laser Damage conference thin-film damage competition was devoted to a survey on the state-of-the-art broadband near-IR multilayer dielectric (MLD) mirrors designed for ultra-short pulsed laser applications. The requirements for the coatings were a minimum reflection of 99.5% at 45-deg incidence angle for S-polarization from 830 nm to 1010 nm and group delay dispersion (GDD) < ± 50fs 2 . The participants were allowed to select the coating materials, coating design, and coating deposition method. Samples were damage tested at a single testing facility to enable direct comparison among the participants using a 25 ± 5 fs optical parametric chirped-pulse amplification (OPCPA) laser system operating at 5 Hz. The testing results from this set of 37 samples showed that dense coatings by ion-beam sputtering (IBS), magnetron sputtering (MS), and electron-beam ion assisted deposition (e-beam IAD) exhibited highest damage initiation onset (laser-induced damage threshold or LIDT) while e-beam coatings were low performers. In addition, multilayer coatings using tantala and/or hafnia as high index materials were top performers. Furthermore, this competition included for the first time the measurement of the damage growth onset (laser-induced damage growth threshold or LDGT). This latter performance metric plays an important role in establishing the safe operational conditions for larger aperture ultrashort pulsed lasers. Information pertaining to the morphology of the damage sites and their evolution under subsequent exposure to different laser fluences leading to damage growth is presented. Finally, not all coating samples in the survey met the GDD requirements stated above and associated measurements are discussed in the context of the present and past thin-film damage competitions focused on similar broadband near-IR MLD coatings.

23 broadband high reflectors↗

NASA NTRS2023

Damage Tolerance Study of Carbon Fiber/Epoxy Sandwich Structure in Support of the SLS Payload Adapter Fitting (PAF)

This study presents experimental results of impact and subsequent compression after impact (CAI) strength testing of sandwich structure representative of most of the acreage of a Payload Adaptor Fitting (PAF) that has been built at NASA’s Marshall Space Flight Center (MSFC). An instrumented drop weight tower was used to inflict different levels of impact damage to specimens. Load versus deflection of impact curves, visual damage, dent depth, damage as ascertained by thermography and cross-sectional microscopy were evaluated as part of the damage resistance of the structure. Compression After Impact (CAI) was performed to assess damage tolerance. The results show that at the amount of visual damage was highly dependent on whether the peel ply was present on the surface of the structure. The peel ply had some effect on the CAI strength values since the specimens with peel ply showed a 14% higher average CAI strength value. For all specimens tested in this study, CAI versus damage and CAI versus impact energy curves were plotted and it was found that damage size was a good indicator of CAI strength. It is suggested to use a b-basis damage tolerance curve based on damage size as a conservative measure of the load carrying capability of the sandwich structure with impact damage.

T1100/3960↗