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Improved tolerance of composites to impact damage achieved using acoustic response model to characterize dynamics of damage mechanism. Model based on assumption that in addition to classical mechanical properties, damage mechanism depends on acoustic properties of composite material. Use of model results in more-impact-resistant composite structure.
This contract reviewed the available literature on mechanisms of low velocity impact damage in filament wound rocket motor cases, MDE methods to quantify damage, critical coupon level test methods, manufacturing and material process variables and empirical and analytical modeling off impact damage. The critical design properties for rocket motor cases are biaxial hoop and axial tensile strength. Low velocity impact damage is insidious because it can create serious nonvisible damage at very low impact velocities. In thick rocket motor cases the prevalent low velocity impact damage is fiber fracture and matrix cracking adjacent to the front face. In contrast, low velocity loading of thin wall cylinders induces flexure, depending on span length and the flexure induces delamination and tensile cracking on the back face wall opposed to impact occurs due to flexural stresses imposed by impact loading. Important NDE methods for rocket motor cases are non-contacting methods that allow inspection from one side. Among these are vibrothermography, and pulse-echo methods based on acoustic-ultrasonic methods. High resolution techniques such as x-ray computed tomography appear to have merit for accurate geometrical characterization of local damage to support development of analytical models of micromechanics. The challenge of coupon level testing is to reproduce the biaxial stress state that the full scale article experiences, and to determine how to scale the composite structure to model full sized behavior. Biaxial tensile testing has been performed by uniaxially tensile loading internally pressurized cylinders. This is experimentally difficult due to gripping problems and pressure containment. Much prior work focused on uniaxial tensile testing of model filament wound cylinders. Interpretation of the results of some studies is complicated by the fact that the fabrication process did not duplicate full scale manufacturing. It is difficult to scale results from testing subscale cylinders since there are significant differences in out time of the resins relative to full scale cylinder fabrication, differences in hoop fiber tensioning and unsatisfactory coupon configurations. It appears that development of a new test method for subscale cylinders is merited. Damage tolerance may be improved by material optimization that uses fiber treatments and matrix modifications to control the fiber matrix interface bonding. It is difficult to develop process optimization in subscale cylinders without also modeling the longer out times resins experience in full scale testing. A major breakthrough in characterizing the effect of impact damage on residual strength, and understanding how to scale results of subscale evaluations, will be a sound micromechanical model that described progressive failure of the composite. Such models will utilize a three dimensional stress analysis due to the complex nature of low velocity impact stresses in thick composites. When these models are coupled with non-contact NDE methods that geometrically characterize the damage and acoustic methods that characterize the effective local elastic properties, accurate assessment of residual strength from impact damage may be possible. Directions for further development are suggested.
A model is presented which predicts the stress-strain behavior of continuous fiber reinforced laminated composites in the presence of microstructural damage. The model is based on the concept of continuum damage mechanics and uses internal state variables to characterize the various damage modes. The associated internal state variable growth laws are mathematical models of the loading history induced development of microstructural damage. The model is demonstrated by using it to predict the response of damaged AS-4/3502 graphite/epoxy laminate panels.
The scope of this dissertation is to develop and apply x ray attenuation measurement systems that are capable of: (1) characterizing density variations in high-temperature materials, e.g., monolithic ceramics, ceramic and intermetallic matrix composites, and (2) noninvasively monitoring damage accumulation and failure sequences in ceramic matrix composites under room temperature tensile testing. This dissertation results in the development of: (1) a point scan digital radiography system, and (2) an in-situ x ray material testing system. Radiographic evaluation before, during, and after loading shows the effect of preexisting volume flaws on the fracture behavior of composites. Results show that x ray film radiography can monitor damage accumulation during tensile loading. Matrix cracking, fiber matrix debonding, fiber bridging, and fiber pullout are imaged throughout the tensile loading of the specimens. Further in-situ radiography is found to be a practical technique for estimating interfacial shear strength between the silicon carbide fibers and the reaction bonded silicon nitride matrix. It is concluded that pretest, in-situ, and post test x ray imaging can provide for greater understanding of ceramic matrix composite mechanical behavior.
All spacecraft use some sort of thermal insulation in their design, which is usually placed on the spacecraft’s exterior. As such, it is highly susceptible to high-speed impacts by meteoroids and orbital debris. These high-speed impacts can damage the insulation to a point where the protection it offers is below acceptable limits. It is, therefore, important to be able to characterize expected TPS damage levels stemming from such high-speed impacts. In a recent paper, we presented the results of a study that sought to characterize the high-speed impact damage that would be sustained by two thermal protection materials that have recently gained attention for possible use in interplanetary missions. As part of the analyses performed, ballistic limit equations for these materials were developed using recent high-speed impact test data, and then assessed by comparing their predictions against test data. In this paper, we extend the applicability of the ballistic limit equation for one of those thermal materials beyond the testable regime using the results of series of Smooth Particle Hydrodynamics Code (SPHC) impact simulations at velocities in excess of 10 km/s. When the predictions of the updated and expanded BLE were compared against the results of the SPHC runs, the predictions were seen to be consistent with the data: non-perforation data points were typically below the BLE curves, while perforation data points were typically above them.
Two computational methods are presented that enable a characterization of corrosion damage to be performed from thermal response measurements derived from a standard flash thermographic inspection. The first is based upon a one dimensional analytical solution to the heat diffusion equation and presumes the lateral extent of damage is large compared to the residual structural thickness, such that lateral heat diffusion effects can be considered insignificant. The second proposed method, based on a finite element optimization scheme, addresses the more general case where these conditions are not met. Results from an experimental application are given to illustrate the precision, robustness and practical efficacy of both methods.
Composite materials have been frequently used in aerospace vehicles. Very often defects are inherited during the manufacture and damages are inherited during the construction and services. It becomes critical to understand the mechanical behavior of such composite structure before it can be further used. One good example of these composite structures is the cylindrical bottle of solid rocket motor case with accidental impact damages. Since the replacement of this cylindrical bottle is expensive, it is valuable to know how the damages affects the material, and how it can be repaired. To reach this goal, the damage must be characterized and the stress/strain field must be carefully analyzed. First the damage area, due to impact, is surveyed and identified with a shearography technique which uses the principle of speckle shearing interferometry to measure displacement gradient. Within the damage area of a composite laminate, such as the bottle of solid rocket motor case, all layers are considered to be degraded. Once a lamina being degraded the stiffness as well as strength will be drastically decreased. It becomes a critical area of failure to the whole bottle. And hence the stress/strain field within and around a damage should be accurately evaluated for failure prediction. To investigate the stress/strain field around damages a Hybrid-Numerical method which combines experimental measurement and finite element analysis is used. It is known the stress or strain at the singular point can not be accurately measured by an experimental technique. Nevertheless, if the location is far away from the singular spot, the displacement can be found accurately. Since it reflects the true displacement field locally regardless of the boundary conditions, it is an excellent input data for a finite element analysis to replace the usually assumed boundary conditions. Therefore, the Hybrid-Numerical method is chosen to avoid the difficulty and to take advantage of both experimental technique and finite element analysis. Experimentally, the digital image correlation technique is employed to measure the displacement field. It is done by comparing two digitized images, before and after loading. Numerically, the finite element program, ABAQUS (version 5.2), is used to analyze the stress and strain field. It takes advantage of the high speed and huge memory size of modern supercomputer, CRAY Y-MP, at NASA Marshall Space Flight Center.
This paper describes the damage structure induced in natural CaF2 by the electron beam when using TEM. The observed 10-20 nm periodic features with coherent fringe patterns and the pronounced loss of fluorine found after the TEM exposure of 100-line-oriented and 111-oriented sections of CaF2 provides support for the mechanism of damage by decomposition of CaF2 into 2F and Ca, with the Ca precipitates maintaining a close topotaxial relationship with the parent CaF2.
Four main tasks were accomplished. The first three tasks were related to the goal of measuring the degradation of the insulating capabilities of Space Station multilayer insulation (MLI) due to simulated space debris impacts at hypervelocities. The last task was associated with critically reviewing a Boeing document on the fracture characteristics of the Space Station pressure wall when subjected to a simulated hypervelocity space debris impact. In Task 1, a thermal test procedure for impact damaged MLI specimens was written. In Task 2, damaged MLI specimens were prepared. In Task 3, a computer program was written to simulate MLI thermal tests. In Task 4, the author reviewed a Boeing document describing hypervelocity impact testing on biaxially stressed plates.
The impact damage response of two thermoplastic material systems were compared over a range of impact energies. Eight-inch-square impact specimens with a 24-ply quasi-isotropic layup were manufactured from TC1225 LMPAEK T700G from Toray Industries and APC AS4D/PEKK-FC from Solvay. The effect of the degree of crystallinity (DOC) on the damage response was also investigated using a third set of specimens from the Toray material manufactured with reduced crystallinity. Using a combination of data obtained from X-ray computed tomography (CT) scans and ultrasonic testing (UT), detailed damage maps were created for every interface and ply for selected specimens. Using these damage maps, the delamination size, shape, and area were evaluated at each interface. The presence of fractured fibers was also identified on each ply. The LMPAEK material was found to have fewer and smaller delaminations than the PEKK specimens for impacts at the same energy. However, the LMPAEK specimens contained a larger number of fiber breaks. A similar trend was observed when comparing the baseline LMPAEK specimens with the low-crystallinity LMPAEK specimens. The low-crystallinity specimens had very little delamination but had a large number of plies with fiber breaks. In addition, the LMPAEK specimens often contained lines of fiber fractures in near-surface plies emanating from the contact region that were not present in the PEKK specimens.
The impact damage response of two thermoplastic material systems were compared over a range of impact energies. Eight-inch-square impact specimens with a 24-ply quasi-isotropic layup were manufactured from TC1225 LMPAEK T700G from Toray Industries and APC AS4D/PEKK-FC from Solvay. The effect of the degree of crystallinity (DOC) on the damage response was also investigated using a third set of specimens from the Toray material manufactured with reduced crystallinity. Using a combination of data obtained from X-ray computed tomography (CT) scans and ultrasonic testing (UT), detailed damage maps were created for every interface and ply for selected specimens. Using these damage maps, the delamination size, shape, and area were evaluated at each interface. The presence of fractured fibers was also identified on each ply. The LMPAEK material was found to have fewer and smaller delaminations than the PEKK specimens for impacts at the same energy. However, the LMPAEK specimens contained a larger number of fiber breaks. A similar trend was observed when comparing the baseline LMPAEK specimens with the low-crystallinity LMPAEK specimens. The low-crystallinity specimens had very little delamination but had a large number of plies with fiber breaks. In addition, the LMPAEK specimens often contained lines of fiber fractures in near-surface plies emanating from the contact region that were not present in the PEKK specimens.
Verifying the structural integrity of aeronautical vehicles is of critical importance for the safety of passengers and crew. When operating in a densely populated urban area, pedestrian safety and collateral damage to buildings and other infrastructure also become important concerns. Damage modes, including fatigue from an increased frequency of take-off and landing cycles and a higher probability of impacts from bird strikes, also pose different failure risks as compared to commercial long-haul aircraft and thus require a change in structural health monitoring philosophy. This presentation will review the state of the art in structural health monitoring with an eye toward applications for vertical lift systems operated in the urban environment. Structural health monitoring methods including eddy current, fiber optic, ultrasonic plate wave, surface acoustic wave and electrical impedance tomography will be explored for use in on-board monitoring of impact and overstrain events as well as damage detection and characterization. Infusion of the data into an early warning system to help ensure damage will not propagate to failure during flight will also be discussed.
Soon after the Columbia Accident Investigation Board (CAIB) began their study of the space shuttle Columbia accident, "physics-based" analyses using LS-DYNA were applied to characterize the expected damage to the Reinforced Carbon-Carbon (RCC) leading edge from high-speed foam impacts. Forensic evidence quickly led CAIB investigators to concentrate on the left wing leading edge RCC panels. This paper will concentrate on the test of the left-wing RCC panel 8 conducted at Southwest Research Institute (SwRI) and the correlation with an LS-DYNA analysis. The successful correlation of the LS-DYNA model has resulted in the use of LS-DYNA as a predictive tool for characterizing the threshold of damage for impacts of various debris such as foam, ice, and ablators onto the RCC leading edge for shuttle return-to-flight.
Blast overpressure is the predominant source of ground damage posed by potentially hazardous asteroid strikes. Estimates of the extent, severity, and likelihoods of potential blast damage regions will be one of the key metrics needed to mount civil defense or disaster response plans in the face of an impending impact. However, there are many inherent sources of uncertainty in evaluating the damage, both in characterizing the properties of the incoming object and in the approaches used to model the entry/impact and resulting damage, which make it difficult to produce a single ‘accurate’ or ‘best guess’ prediction of ground damage. The current 2021 PDC hypothetical impact scenario poses a particular challenge due to its short warning time. The need for rapid disaster response to prepare for an immanent impact, combined with lack of observational opportunities to refine basic knowledge about the object’s basic size and properties, make understanding the range and relative likelihood of consequences particularly critical. The potential damage caused by these blasts can be evaluated using a range of modeling and simulation approaches and levels of fidelity. Fast-running engineering-level models can be used to run large numbers of probabilistically sampled cases covering wide variations of uncertain properties or parameters. High-fidelity simulations, on the other hand, can capture more detailed/accurate blast physics, but can only be performed for a small selection of specific cases, requiring many assumptions to be made about the initial object and its unpredictable entry/breakup characteristics. In order to provide a more complete picture of the potential threat for effective disaster response, both types of analysis need to be employed together. In this approach, high-fidelity simulations are used to refine and anchor engineering models, and the probabilistic engineering models are used to evaluate broad parameters spaces and guide selection of the most pertinent simulation cases for a given scenario. This presentation expands upon the probabilistic asteroid impact risk assessments being performed as part of the 2021 PDC hypothetical impact exercise, focusing on key aspects of blast damage modeling uncertainties and sensitivities. We review the current modeling and simulation approaches employed in the current assessment, compare the relative levels of uncertainty stemming from each main element of the problem (i.e., knowledge of the asteroid properties, modeling of the atmospheric entry/breakup and airburst, and estimates of the ground damage from the resulting blasts waves), and highlight any notable trends and sensitivities for the current scenario case.
While the study of compression after impact of laminated composites has been under consideration for many years, the complexity of the damage initiated by low velocity impact has not lent itself to simple predictive models for compression strength. The damage modes due to non-penetrating, low velocity impact by large diameter objects can be simulated using quasi-static three-point bending. The resulting damage modes are less coupled and more easily characterized than actual impact damage modes. This study includes the compression testing of specimens with well documented initial damage states obtained from three-point bend testing. Compression strengths and failure modes were obtained for quasi-isotropic stacking sequences from 0.24 to 1.1 inches thick with both grouped and interspersed ply stacking. Initial damage prior to compression testing was divided into four classifications based on the type, extent, and location of the damage. These classifications are multiple through-thickness delaminations, isolated delamination, damage near the surface, and matrix cracks. Specimens from each classification were compared to specimens tested without initial damage in order to determine the effects of the initial damage on the final compression strength and failure modes. A finite element analysis was used to aid in the understanding and explanation of the experimental results.
Microelectronic and photonic systems in the natural space environment are bombarded by a variety of charged particles including electrons, trapped protons, cosmic rays, and solar particles (protons and other heavy ions). These incident particles cause both ionizing and non-ionizing effects when traversing a device, and the effects can be either transient or permanent. The vast majority of the kinetic energy of an incident proton is lost to ionization, creating the single event effects (SEES) and total ionizing dose (TID) effects. However, the small portion of energy lost in non-ionizing processes causes atoms to be removed from their lattice sites and form permanent electrically active defects in semiconductor materials. These defects, i.e., "displacement damage," can significantly degrade device performance. In general, most of the displacement damage effects in the natural space environment can be attributed to protons since they are plentiful and extremely energetic (and therefore not readily shielded against). For this reason, we consider only proton induced displacement damage in this course. (Nevertheless, we identify solar cells as an important example of a case where both electron and proton damage can be important since only very light shielding is feasible.) The interested reader is encouraged to explore the three previous NSREC and RADECS short courses which also treat displacement damage issues for satellite applications. Part A of this segment of the short course introduces the space environment, proton shielding issues, and requirements specifications for proton-rich environments. In order to exercise the displacement damage analysis tools for on-orbit performance predictions, the requirements document must provide the relevant proton spectra in addition to the usual total ionizing dose-depth curves. Ion-solid interactions and the nature of the displacement damage they generate have been studied extensively for over half a century, yet they still remain a subject of investigation. In this section, a description of the mechanisms by which displacement damage is produced will be followed by a summary of the major consequences for device performance in a space environment. Often the degradation of a device parameter can be characterized by a damage factor (measured in a laboratory using monoenergetic protons) that is simply the change in a particular electrical or optical parameter per unit proton fluence. In addition, we will describe the concept of a non-ionizing energy loss rate (NIEL) which quantifies that portion of the energy lost by an incident ion that goes into displacements. It has been calculated as a function of proton energy, and is analogous to (and has the same units as) the linear energy transfer (LET) for ionizing energy. We will discover that, to first order, the calculated NIEL describes the energy dependence of the measured device damage factors. This observation provides the basis for predicting proton induced device degradation in a space environment based on both the calculated NIEL and relatively few laboratory test measurements. The methodology of such on-orbit device performance predictions will be described, as well as the limitations. Several classes of devices for which displacement damage is a significant (if not the dominant) mode of radiation induced degradation will be presented.
Predicting cancer risk associated with cosmic radiation remains a mission-critical challenge for NASA radiation health scientists and mission planners. Epidemiological data are lacking and risk methods do not take individual radiation sensitivity into account. In our approach we hypothesize that genetic factors strongly influence risk of cancer from space radiation and that biomarkers reflecting DNA damage and cell death are ideal tools to predict risk and monitor potential health effects post-flight. At this workshop, we will be reporting the work we have done over the first 9 months of this proposal. Skin cells from 15 different strains of mice already characterized for radiation-induced cancer sensitivity (B6C3F; BALB/cByJ, C57BL/6J, CBA/CaJ, C3H/HeMsNrsf), and 10 strains from the DOE collaborative cross-mouse model were expanded from ear biopsy and cultivated until Passage 3. On average, 3 males and 3 females for each strain were expanded and frozen for further characterization at the NSRL beam line during the NSRL16C run for three LET (350 MeV/n Si, 350 MeV/n Ar and 600 MeV/n Fe) and two ion fluences (1 and 3 particles per cell). The mice work has established new metrics for the usage of Radiation Induced Foci as a marker for various aspect of DNA repair deficiencies. In year 2, we propose to continue characterization of the mouse lines with low LET to identify loci specific to high- versus low- LET and establish genetic linkage for the various DNA repair biomarkers. Correlation with cancer risk from each animals strain and gender will also be investigated. On the human side, we will start characterizing the DNA damage response induced ex-vivo in 200 human's blood donors for radiation sensitivity with a tentative 500 donors by the end of this project. All ex-vivo phenotypic data will be correlated to genetic characterization of each individual human donors using SNP arrays characterization as done for mice. Similarly, ex-vivo phenotypic features from mice will be associated to cancer risk, to identify which biomarkers correlate the most with cancer risk. Genetic traits across humans will also be associated to radiation phenotypic features as a function of age and gender.
Prognostics of large composite structures is a topic of increasing interest in the field of structural health monitoring for aerospace, civil, and mechanical systems. Along with recent advancements in real-time structural health data acquisition and processing for damage detection and characterization, model-based stochastic methods for life prediction are showing promising results in the literature. Among various model-based approaches, particle-filtering algorithms are particularly capable in coping with uncertainties associated with the process. These include uncertainties about information on the damage extent and the inherent uncertainties of the damage propagation process. Some efforts have shown successful applications of particle filtering-based frameworks for predicting the matrix crack evolution and structural stiffness degradation caused by repetitive fatigue loads. Effects of other damage modes such as delamination, however, are not incorporated in these works. It is well established that delamination and matrix cracks not only co-exist in most laminate structures during the fatigue degradation process but also affect each other's progression. Furthermore, delamination significantly alters the stress-state in the laminates and accelerates the material degradation leading to catastrophic failure. Therefore, the work presented herein proposes a particle filtering-based framework for predicting a structure's remaining useful life with consideration of multiple co-existing damage-mechanisms. The framework uses an energy-based model from the composite modeling literature. The multiple damage-mode model has been shown to suitably estimate the energy release rate of cross-ply laminates as affected by matrix cracks and delamination modes. The model is also able to estimate the reduction in stiffness of the damaged laminate. This information is then used in the algorithms for life prediction capabilities. First, a brief summary of the energy-based damage model is provided. Then, the paper describes how the model is embedded within the prognostic framework and how the prognostics performance is assessed using observations from run-to-failure experiments