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At least 145 records · Page 8

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NASA NTRS2017

Tutorial for Collecting and Processing Images of Composite Structures to Determine the Fiber Volume Fraction

Fiber-reinforced composite structures have become more common in aerospace components due to their light weight and structural efficiency. In general, the strength and stiffness of a composite structure are directly related to the fiber volume fraction, which is defined as the fraction of fiber volume to total volume of the composite. The most common method to measure the fiber volume fraction is acid digestion, which is a useful method when the total weight of the composite, the fiber weight, and the total weight can easily be obtained. However, acid digestion is a destructive test, so the material will no longer be available for additional characterization. Acid digestion can also be difficult to machine out specific components of a composite structure with complex geometries. These disadvantages of acid digestion led the author to develop a method to calculate the fiber volume fraction. The developed method uses optical microscopy to calculate the fiber area fraction based on images of the cross section of the composite. The fiber area fraction and fiber volume fraction are understood to be the same, based on the assumption that the shape and size of the fibers are consistent in the depth of the composite. This tutorial explains the developed method for optically determining fiber area fraction performed at NASA Langley Research Center.

Conklin, Lindsey↗

NASA NTRS1990

Micro-mechanical analysis of damage growth and fracture in discontinuous fiber reinforced metal matrix composites

The near-crack-tip stresses in any planar coupon of arbitrary geometry subjected to mode 1 loading may be equated to those in an infinite center-cracked panel subjected to the appropriate equivalent remote biaxial stresses (ERBS). Since this process can be done for all such mode 1 coupons, attention may be focused on the behavior of the equivalent infinite cracked panel. To calculate the ERBS, the constant term in the series expansion of the crack-tip stress must be retained. It is proposed that the ERBS may be used quantitatively to explain different fracture phenomena such as crack branching.

Goree, James G.↗

DOE OSTI2022

A novel approach for tetrahedral-element-based finite element simulations of anisotropic hyperelastic intervertebral disc behavior

Intervertebral discs are microstructurally complex spinal tissues that add greatly to the flexibility and mechanical strength of the human spine. Attempting to provide an adjustable basis for capturing a wide range of mechanical characteristics and to better address known challenges of numerical modeling of the disc, we present a robust finite-element-based model formulation for spinal segments in a hyperelastic framework using tetrahedral elements. We evaluate the model stability and accuracy using numerical simulations, with particular attention to the degenerated intervertebral discs and their likely skewed and narrowed geometry. To this end, 1) annulus fibrosus is modeled as a fiber-reinforced Mooney-Rivlin type solid for numerical analysis. 2) An adaptive state-variable dependent explicit time step is proposed and utilized here as a computationally efficient alternative to theoretical estimates. 3) Tetrahedral-element-based FE models for spinal segments under various loading conditions are evaluated for their use in robust numerical simulations. For flexion, extension, lateral bending, and axial rotation load cases, numerical simulations reveal that a suitable framework based on tetrahedral elements can provide greater stability and flexibility concerning geometrical meshing over commonly employed hexahedral-element-based ones for representation and study of spinal segments in various stages of degeneration.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1983

Analysis of a hybrid, uni-directional laminate with damage

The fracture behavior of hybrid (buffer strip) laminated composites is predicted by a novel method in terms of material properties, geometry, and internal damage. Attention is given to the cases of broken fibers in a unidirectional half-plane, adjoined half-planes having different fiber and matrix properties, and the solution of two half-planes bounding a third, distinct region of finite width. The analysis is based on a materials modeling approach using the classical shear-lag assumption to represent the stress transfer between fibers. Explicit fiber and matrix properties of the three regions are retained, and changes in the laminate behavior as a function of the material properties, buffer strip width and initial crack length are discussed.

Goree, J. G.↗

NASA NTRS1991

Development of braided rope seals for hypersonic engine applications. Part 2: Flow modeling

Two models based on the Kozeny-Carmen equation were developed to analyze the fluid flow through a new class of braided rope seals under development for advanced hypersonic engines. A hybrid seal geometry consisting of a braided sleeve and a substantial amount of longitudinal fibers with high packing density was selected for development based on its low leakage rates. The models developed allow prediction of the gas leakage rate as a function of fiber diameter, fiber packing density, gas properties, and pressure drop across the seal.

Mutharasan, Rajakkannu↗

NASA NTRS1991

Development of braided rope seals for hypersonic engine applications. II - Flow modeling

Mutharasan, Rajakkannu↗

NASA NTRS2014

Carbon Fiber Foam Composites and Methods for Making the Same

Exemplary embodiments provide methods and apparatus of forming fibrous carbon foams (FCFs). In one embodiment, FCFs can be formed by flowing a fuel rich gas mixture over a catalytic material and components to be encapsulated in a mold to form composite carbon fibers, each composite carbon fiber having a carbon phase grown to encapsulate the component in situ. The composite carbon fibers can be intertwined with one another to form FCFs having a geometry according to the mold.

Leseman, Zayd Chad↗

DOE OSTI2025

Macro-level mechanical interlocking: A rapid joining approach for additively manufactured compression molded composite panels

Composite joining typically involves multiple steps, such as drilling and surface treatment, as part of the manufacturing process, which leads to low throughput and long cycle times. In the present study, we demonstrated a macro-level mechanical interlocking (MI) based, rapid joining technique to assemble additively manufactured compression molded (AMCM) panels, enabling the production of parts larger than the mold dimensions. Composite panels made of 20 wt% short carbon fiber reinforced acrylonitrile butadiene styrene (CF/ABS) were joined using MI features of various geometries, namely tree (TR), dovetail (Dov), rectangle 2 (Rect2), and rectangle 1 (Rect1), and their in-plane strength was evaluated. The resultant strength of the tested MI joints reached up to 74 % of the baseline tensile strength (i.e., the ‘no joint’ case). Observations from optical and scanning electron microscopy revealed inadequate polymer diffusion between the adherends, indicating that the joint strength was primarily derived from mechanical interlocking. Additionally, the fracture surfaces exhibited stress-whitening marks, which were characterized using differential scanning calorimetry (DSC). The increase in melting enthalpy suggested local stretching of polymer chains due to MI. Finite element analysis (FEA) indicated that the Rect1 MI feature, which generated the lowest stress concentration, outperformed the others in terms of joint strength, achieving 42 MPa. As a demonstration of the MI joining method, a battery box tray measuring 108 cm × 34 cm using a mold with an effective dimension of 36 cm × 34 cm successfully manufactured, resulting in a part with an area three times larger than the mold. In conclusion, this study presents a promising approach to improving composite joining techniques while minimizing production complexities.

In-plane joining↗

NASA NTRS1978

The compressive failure of graphite/epoxy plates with circular holes

The behavior of fiber reinforced composite plates containing a circular cutout was characterized in terms of geometry (thickness, width, hole diameter), and material properties (bending/extensional stiffness). Results were incorporated in a data base for use by designers in determining the ultimate strength of such a structure. Two thicknesses, 24 plies and 48 plies were chosen to differentiate between buckling and strength failures due to the presence of a cutout. Consistent post-buckling strength was exhibited by both laminate configurations.

Knauss, J. F.↗

NASA NTRS1989

Non-steady state cracking in ceramic matrix composites

A micromechanics analytical model based on the consistent shear lag theory is developed for predicting the failure modes in a fiber-reinforced unidirectional ceramic matrix composite. The model accounts for the relatively large matrix stiffness. The fiber and matrix stresses are established as functions of the applied stress, crack geometry, and most importantly, the microstructural properties of the constituents. From the predicted stress, the mode of failure is established based on the point stress criterion. The role of the microstructural properties on the failure mode and ultimate strength is assessed.

Dharani, L. R.↗

NASA NTRS1989

Elastic crack bridging in ceramic and intermetallic matrix composites

A micromechanics analytical model based on the consistent shear lag theory is developed for predicting the failure modes in a fiber reinforced unidirectional ceramic and intermetallic matrix composite. The model accounts for the relatively large matrix stiffness. The fiber and matrix stresses are established as functions of the applied stress, crack geometry, and most importantly, the microstructural properties of the constituents. From the predicted stress, the mode of failure is established based on the point stress criterion.

Dharani, L. R.↗

NASA NTRS1996

Fiber Optic Sensors for Smart Materials and Structures

In this paper we describe recently developed fiber sensors which are capable of monitoring the health of smart-structures. The unobstrusive geometry of these sensors make them an excellent choice for embedding the sensor in composite materials to measure internal states of strain in structures and materials. Some of these sensors have gage lengths that can be tailored from tens of microns to many meters. We will describe various demodulation schemes (Pseudo-Heterodyne, Synthetic-Heterodyne, Homodyne, Differential-Cross Multiplier, and Single Channel Phase-Tracker) to obtain high bandwidth measurements, enabling measurement of static to high frequency impact generated strains with a dynamic response exceeding tens of thousands of microstrains. In addition, we will show that we can tailor the fiber sensor to either measure only strain and reject temperature response or measure only the temperature, or measure both temperature and strain simultaneously. We will also demonstrate the ability to measure multiple strain components inside a host simultaneously using a single fiber sensor embedded in the host using a certain sensor type and transverse strain immunity using another sensor type. Additionally we will show the ability to measure temperature up to 100 C using fiber optic sensors.

Singh, H.↗

NASA NTRS1990

Innovative design of composite structures: The use of curvilinear fiber format in structural design of composites

The influence is investigated of a curvilinear fiber format on load carrying capacity of a layered fiber reinforced plate with a centrally located hole. A curvilinear fiber format is descriptive of layers in a laminate having fibers which are aligned with the principal stress directions in those layers. Laminates of five curvilinear fiber format designs and four straightline fiber format designs are considered. A quasi-isotropic laminate having a straightline fiber format is used to define a baseline design for comparison with the other laminate designs. Four different plate geometries are considered and differentiated by two values of hole diameter/plate width equal to 1/6 and 1/3, and two values of plate length/plate width equal to 2 and 1. With the plates under uniaxial tensile loading on two opposing edges, alignment of fibers in the curvilinear layers with the principal stress directions is determined analytically by an iteration procedure. In-plane tensile load capacity is computed for all of the laminate designs using a finite element analysis method. A maximum strain failure criterion and the Tsai-Wu failure criterion are applied to determine failure loads and failure modes. Resistance to buckling of the laminate designs to uniaxial compressive loading is analyzed using the commercial code Engineering Analysis Language. Results indicate that the curvilinear fiber format laminates have higher in-plane tensile load capacity and comparable buckling resistance relative to the straightline fiber format laminates.

Charette, R. F.↗

NASA NTRSDate not supplied

3D Woven Mid-Density Carbon Phenolic (3MDCP) Thermal Protection System Development

3-Dimensionally Woven, Mid-Density, Carbon Phenolic (3MDCP) Thermal Protection System (TPS) material is derived from the dual layer 3D woven Heatshield for Extreme Entry Environment Technology (HEEET) material. The baseline 3MDCP design is a single piece thermal protection system that avoids the manufacturing and certification challenges associated with a tiled configuration. 3MDCP is targeted for very aggressive entry environments such as high-speed sample return missions to Earth and missions to Saturn, Venus and the ice giants. A 3MDCP heatshield begins as a flat woven preform that is formed to a given heatshield shape and then infused with phenolic resin. NASA Ames, in collaboration with TEAM Inc. (weaving) and Fiber Materials Inc. (both Spirit AeroSystems Companies) have been developing and demonstrating the manufacturing processes to fabricate a 3MDCP heatshield at a diameter of 1.25 meters. The process of forming the flat woven preform into the final heatshield shape, a sphere-cone geometry, involves local movement of the yarns in the weave. This results in a single piece heatshield with continuous fibers, albeit with property variations between different regions on the heatshield. This presentation will provide a high-level status of 3MDCP development. This will include an overview of the manufacturing processes, with an emphasis on the impact of forming on fiber orientation, material properties and performance. The presentation will layout the plan for testing to assess the impact of forming on properties and review preliminary data comparing properties of flat to formed materials.

Thermal Protection System↗

NASA NTRS1994

Fabric geometry distortion during composites processing

Waviness and tow misalignment are often cited as possible causes of data scatter and lower compression stiffness and strength in textile composites. Strength differences of as much as 40 percent have been seen in composites that appear to have the same basic material and structural properties -- i.e., yarn orientation, yarn size, interlacing geometry. Fabric geometry distortion has been suggested as a possible reason for this discrepancy, but little quantitative data or substantial evidence exists. The focus of this research is to contribute to the present understanding of the causes and effects of geometric distortion in textile composites. The initial part of the study was an attempt to gather qualitative information on a variety of textile structures. Existing and new samples confirmed that structures with a significant direction presence would be more susceptible to distortion due to the compaction process. Thus, uniweaves (fiber vol frac: 54-72 percent) biaxial braids (vf: 34-58 percent) demonstrated very little fabric geometry distortion. In stitched panels, only slight buckling of z-direction stitches was observed, primarily near the surface. In contrast, for structures with high compaction ratios -- e.g., large cylindrical yarns (2.5:1) orpowder towpreg (4:1) -- there were visible distortions where previously smooth and periodic undulations were transformed to abrupt changes in direction. A controlled study of the effect of forming pressure on distortion was conducted on type 162 glass plain weave fabrics. Panels (6 x 6 in) were produced via a resin infusion type setup, but with an EPON 815 epoxy resin. Pressures ranging from hand layup to 200 psi were used (vf: 34-54 percent). Photomicrographs indicated that at pressures up to 50 psi, large changes in thickness were due primarily to resin squeeze out. At higher pressures, when intimate contact was made between the layers, there was some tow flattening and in-plane shifting to optimize nesting. However, even at 200 psi the period and amplitude of the tow undulation remained constant, suggesting that for this relatively fine fabric, distortions from compaction were not a problem. Because of the interest in using larger tows (to reduce cost) and more complex structures, tests were also run on 2D triaxial glass braid (113 yd/lb at 0, 225 yd/lb at +/- 45). Forming pressures of 20, 50, 200, and 500 psi were used, and short block compression tests were run. The 500 psi specimen had a 10 percent decrease in modulus and an almost 50 percent decrease in strength (vs. 20 psi). Because the total fiber wgt/panel was kept constant, the thickness varied from 0.32 to 0.22 in (49-70 percent vf). Yet, the strength value is clearly below what would be expected, even with the decrease in thickness. Photomicrographs of these samples will be taken to determine if more fabric distortion exists in the 500 psi specimens. Finally, because the ultimate goal is to be able to predict and control distortion in a variety of textile structures, a model compaction test was developed to directly measure the deformation of the tows during compaction. Layers of dry glass fabric were placed in a mold with a clear plexiglass window. The yarn amplitude and period was then calculated using image analysis of the videotaped deformation. Preliminary tests demonstrated the feasibility of this technique for simple fabrics with large tows.

Chen, Julie↗

DOE OSTI2020

Carbon Fiber and Syntactic Foam Hybrid Materials via Core–Shell Material Extrusion Additive Manufacturing

Abstract Biological materials often employ hybrid architectures, such as the core–shell (C–S) motif present in porcupine quills and plant stems, to achieve unique specific properties and performance. Drawing inspiration from these natural materials, a new method to fabricate lightweight and stiff C–S architected filaments is reported. Specifically, a C–S printhead conducive to printing highly loaded fiber‐filled inks, as well as a new low‐density syntactic foam ink, are utilized to 3D‐print C–S architectures consisting of a syntactic epoxy foam core surrounded by a stiff carbon fiber‐reinforced epoxy composite shell. Effective printing of test specimens and structures with controlled geometry, composition, and architecture is demonstrated. The new foam ink exhibits density as low as 0.68 g cm −3 and C–S structures exhibit up to 25% higher specific flexural stiffness ( E 1/3 /ρ) than either constituent alone. Finally, a new mechanical model is presented to predict this performance improvement while accounting for potential eccentricity of the core.

Pack, Robert C.↗

NASA NTRS1993

Determination of plate wave velocities and diffuse field decay rates with braod-band acousto-ultrasonic signals

Lowest symmetric and lowest antisymmetric plate wave modes were excited and identified in broad-band acousto-ultrasonic (AU) signals collected from various high temperature composite materials. Group velocities have been determined for these nearly nondispersive modes. An algorithm has been developed and applied to determine phase velocities and hence dispersion curves for the frequency ranges of the broad-band pulses. It is demonstrated that these data are sensitive to changes in the various stiffness moduli of the materials, in agreement by analogy, with the theoretical and experimental results of Tang and Henneke on fiber reinforced polymers. Diffuse field decay rates have been determined in the same specimen geometries and AU configuration as for the plate wave measurements. These decay rates are of value in assessing degradation such as matrix cracking in ceramic matrix composites. In addition, we verify that diffuse field decay rates respond to fiber/matrix interfacial shear strength and density in ceramic matrix composites. This work shows that velocity/stiffness and decay rate measurements can be obtained in the same set of AU experiments for characterizing materials and in specimens with geometries useful for mechanical measurements.

Kautz, Harold E.↗

NASA NTRS1998

Graphite Fiber Textile Preform/Cooper Matrix Composites

The purpose of this research was to produce a finned tube constructed of a highly conductive braided graphite fiber preform infiltrated with a copper matrix. In addition, the tube was to be fabricated with an integral geometry. The preform was integral in the sense that the tube and the fin could be braided to yield one continuous part. This composite component is a candidate for situations with high heat transmitting and radiation requirements. A proof-of-concept finned tube was braided and infiltrated with a copper matrix proving that a viable process was developed to fabricate the desired component. Braiding of high conductivity carbon fibers required much trial-and-error and development of special procedures. There are many tradeoffs between braidability and fiber conductivity. To understand the properties and structure of the braided finned tube, an geometric model of the braid structure was derived. This derivation set the basis for the research because knowing the tow orientations helped decipher the thermal as well as the mechanical and conduction tendencies. Infiltration of the fibers into a copper matrix was a complex procedure, and was performed by TRA, of Salt Lake City, Utah, using a proprietary process. Several batches were fabricated with a final, high quality batch serving as a confirming proof-of-concept.

Filatovs, George J.↗