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NASA NTRS1995

Analysis of the progressive failure of brittle matrix composites

This report investigates two of the most common modes of localized failures, namely, periodic fiber-bridged matrix cracks and transverse matrix cracks. A modification of Daniels' bundle theory is combined with Weibull's weakest link theory to model the statistical distribution of the periodic matrix cracking strength for an individual layer. Results of the model predictions are compared with experimental data from the open literature. Extensions to the model are made to account for possible imperfections within the layer (i.e., nonuniform fiber lengths, irregular crack spacing, and degraded in-situ fiber properties), and the results of these studies are presented. A generalized shear-lag analysis is derived which is capable of modeling the development of transverse matrix cracks in material systems having a general multilayer configuration and under states of full in-plane load. A method for computing the effective elastic properties for the damaged layer at the global level is detailed based upon the solution for the effects of the damage at the local level. This methodology is general in nature and is therefore also applicable to (0(sub m)/90(sub n))(sub s) systems. The characteristic stress-strain response for more general cases is shown to be qualitatively correct (experimental data is not available for a quantitative evaluation), and the damage evolution is recorded in terms of the matrix crack density as a function of the applied strain. Probabilistic effects are introduced to account for the statistical nature of the material strengths, thus allowing cumulative distribution curves for the probability of failure to be generated for each of the example laminates. Additionally, Oh and Finney's classic work on fracture location in brittle materials is extended and combined with the shear-lag analysis. The result is an analytical form for predicting the probability density function for the location of the next transverse crack occurrence within a crack bounded region. The results of this study verified qualitatively the validity of assuming a uniform crack spacing (as was done in the shear-lag model).

Thomas, David J.↗

DOE OSTI2021

Seawater sea-sand engineered/strain-hardening cementitious composites (ECC/SHCC): Assessment and modeling of crack characteristics

Highlights: • A probabilistic model was proposed to model the crack width evolution of SS-ECC at different strain levels. • The Weibull distribution fit the crack width distribution better than the log-normal distribution. • A 5-D representation was proposed to assess the SS-ECC by considering both cracking and mechanical performance. • Larger sea-sand size and lower fiber dosage led to larger crack widths in SS-ECC under the same tensile strain. • 18-mm PE fiber led to larger crack widths in SS-ECC at strain >2%, due to a large fraction of fiber rupture. Seawater sea-sand Engineered Cementitious Composites (SS-ECC) is a new version of ECC for marine constructions facing the scarcity of freshwater and river/manufactured sand. This study aims to assess and model the crack characteristics of SS-ECC, which are critical for its applications with non-corrosive reinforcements. The influence of sea-sand size, fiber length and fiber dosage on the crack characteristics of SS-ECC was explored. A five-dimensional representation was proposed to assess the overall performance of SS-ECC, by comprehensively considering both the crack characteristics (i.e., crack width and its variation) and the mechanical properties (i.e., compressive and tensile properties). A probabilistic model was also proposed to describe the stochastic nature and evolution of crack width, and it can be used to estimate the critical tensile strain on SS-ECC for a given crack-width limit and cumulative probability. The findings and proposed methods can facilitate the design of SS-ECC in marine and coastal structures.

36 MATERIALS SCIENCE↗

NASA NTRS2006

Evaluation Of Risk And Possible Mitigation Schemes For Previously Unidentified Hazards

This report presents the results of arc track testing conducted to determine if such a transfer of power to un-energized wires is possible and/or likely during an arcing event, and to evaluate an array of protection schemes that may significantly reduce the possibility of such a transfer. The results of these experiments may be useful for determining the level of protection necessary to guard against spurious voltage and current being applied to safety critical circuits. It was not the purpose of these experiments to determine the probability of the initiation of an arc track event only if an initiation did occur could it cause the undesired event: an inadvertent thruster firing. The primary wire insulation used in the Orbiter is aromatic polyimide, or Kapton , a construction known to arc track under certain conditions [3]. Previous Boeing testing has shown that arc tracks can initiate in aromatic polyimide insulated 28 volts direct current (VDC) power circuits using more realistic techniques such as chafing with an aluminum blade (simulating the corner of an avionics box or lip of a wire tray), or vibration of an aluminum plate against a wire bundle [4]. Therefore, an arc initiation technique was chosen that provided a reliable and consistent technique of starting the arc and not a realistic simulation of a scenario on the vehicle. Once an arc is initiated, the current, power and propagation characteristics of the arc depend on the power source, wire gauge and insulation type, circuit protection and series resistance rather than type of initiation. The initiation method employed for these tests was applying an oil and graphite mixture to the ends of a powered twisted pair wire. The flight configuration of the heater circuits, the fuel/oxider (or ox) wire, and the RCS jet solenoid were modeled in the test configuration so that the behavior of these components during an arcing event could be studied. To determine if coil activation would occur with various protection wire schemes, 145 tests were conducted using various fuel/ox wire alternatives (shielded and unshielded) and/or different combinations of polytetrafuloroethylene (PTFE), Mystik tape and convoluted wraps to prevent unwanted coil activation. Test results were evaluated along with other pertinent data and information to develop a mitigation strategy for an inadvertent RCS firing. The SSP evaluated civilian aircraft wiring failures to search for aging trends in assessing the wire-short hazard. Appendix 2 applies Weibull statistical methods to the same data with a similar purpose.

Linzey, William↗

DOE OSTI2022

Initial ASME code rule analysis on Simple and Full assessment

ASME & ASTM codes present simple and full assessment methodologies to qualify nuclear grade graphite components. This report explains the theory behind the statistical portion of the codes and describes the issues discussed in a 2020 workshop in the simple assessment, as well as the full assessment. The methodology for the full assessment was developed by Hindley []. He used a validation methodology to match the experimental average failure load of test specimens from several geometries to the calculated 50% POF load to tune the grouping criteria parameters based on an RMSE penalty function. The grouping criteria consists of a minimum volume to satisfy the weakest link theory of the Weibull distribution and a minimum stress range parameter. Hindley’s work found a minimum link volume of 10 times the grain size and a stress range parameter of 7% [satisfy the validation requirements. Several studies found that the link volume of 10 times the grain size was not satisfactory for the volume grouping criteria for graphite grades with fine grains. ASME 2021 code adopted a new volume grouping criteria based on fracture toughness for calculation of the process zone volume. However, errors were found in the ASME 2021 code process zone volume equation and the question is now open as to what volume grouping criteria is satisfactory. This report presents results from sensitivity studies that were done to evaluate the volume grouping criteria effect on the full assessment POF. This report also presents results from sensitivity studies on other aspects of the code that affect the POF, the mesh size and the choice of the Weibull threshold parameter. All three sensitivity studies: the volume grouping criteria, the mesh size, and the threshold parameter choice are found to affect the component qualification decision for components of structural reliability class 1 (SRC-1). The sensitivity analysis results are presented in the body of the report for NBG-18, which is the same grade of graphite as Hindley used in his thesis. Results from NBG-17, IG-110, 2114, and PCEA are presented in the Appendix. For NBG-18, it was found that increasing the threshold increases the POF, finer meshes result in higher POFs, and that smaller link volume requirements lead to higher POFs (which is inconsistent with Hindley’s findings). This report proposes a new validation study similar to Hindley’s []. The purpose of the new validation study is to tune the threshold, mesh size and grouping criteria based on results from multiple grades of graphite, including finer grain graphites T220 (1-3 microns) and NG-CT-50 (5 microns). The test specimens will be broken at 3 labs, such that we can measure between lab measurement variability, with at least 5 test specimens per lab such that the within lab uncertainty can also be measured. Hindley’s validation method tried matching the average experimental load with the median. The future study will attempt to match failures at lower percentiles, which would be closer to the SRC POF limit. We are currently looking into what geometries make sense and the best method to measure multi-axial stress states. These design decisions are still being set.

36 MATERIALS SCIENCE↗