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At least 145 records · Page 8

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NASA NTRS2004

Lamb Wave Stiffness Characterization of Composites Undergoing Thermal-Mechanical Aging

The introduction of new, advanced composite materials into aviation systems requires a thorough understanding of the long term effects of combined thermal and mechanical loading upon those materials. Analytical methods investigating the effects of intense thermal heating combined with mechanical loading have been investigated. The damage mechanisms and fatigue lives were dependent on test parameters as well as stress levels. Castelli, et al. identified matrix dominated failure modes for out-of-phase cycling and fiber dominated damage modes for in-phase cycling. In recent years, ultrasonic methods have been developed that can measure the mechanical stiffness of composites. To help evaluate the effect of aging, a suitably designed Lamb wave measurement system is being used to obtain bending and out-of-plane stiffness coefficients of composite laminates undergoing thermal-mechanical loading. The system works by exciting an antisymmetric Lamb wave and calculating the velocity at each frequency from the known transducer separation and the measured time-of-flight. The same peak in the waveforms received at various distances is used to measure the time difference between the signals. The velocity measurements are accurate and repeatable to within 1% resulting in reconstructed stiffness values repeatable to within 4%. Given the material density and plate thickness, the bending and out-of-plane shear stiffnesses are calculated from a reconstruction of the dispersion curve. A mechanical scanner is used to move the sensors over the surface to map the time-of-flight, velocity, or stiffnesses of the entire specimen. Access to only one side of the material is required and no immersion or couplants are required because the sensors are dry coupled to the surface of the plate. In this study, the elastic stiffnesses D(sub 11), D(sub 22), A(sub 44), and A(sub 55) as well as time-of-flight measurements for composite samples that have undergone combined thermal and mechanical aging for a duration of 10,000 hours are reported.

Seale, Michael D.↗

NASA NTRS1946

Numerical procedures for the calculation of the stresses in monocoques III : calculation of the bending moments in fuselage frames

This report deals with the calculation of the bending moments in and the distortions of fuselage rings upon which known concentrated and distributed loads are acting. In the procedure suggested, the ring is divided into a number of beams each having a constant radius of curvature. The forces and moments caused in the end sections of the beams by individual unit displacements of the end sections are listed in a table designated as the operations table in conformity with Southwell's nomenclature. The operations table and the external loads are equivalent to a set of linear equations. For their solution the following three procedures are presented: 1) Southwell's method of systematic relaxations. This is a step-by-step approximation procedure guided by the physical interpretation of the changes in the values of the unknown. 2) The growing unit procedure in which the individual beams are combined successively into beams of increasing length until finally the entire ring becomes a single beam. In each step of the procedure a set of not more than three simultaneous linear equations is solved. 3) Solution of the entire set of simultaneous equations by the methods of the matrix calculus. In order to demonstrate the manner in which the calculations may be carried out, the following numerical examples are worked out: 1) Curved beam with both its end sections rigidly fixed. The load is a concentrated force. 2) Egg-shape ring with symmetric concentrated loads. 3) Circular ring with antisymmetric concentrated loads and shear flow (torsion of the fuselage). 4) Same with V-braces incorporated in the ring. 5) Egg-shape ring with antisymmetric concentrated loads and shear flow (torsion of the fuselage). 6) Same with V-braces incorporated in the ring. The results of these calculations are checked, whenever possible, by calculations carried out according to known methods of analysis. The agreement is found to be good. The amount of work necessary for the solution of ring problems by the methods described in the present report is practically independent of the degree of redundancy of the structure. For this reason the methods are recommended for use particularly in problems of rings having one or more internal bracing elements.

LOADS - FUSELAGES↗

NASA NTRS1979

Global operators for delta functions - Extension to scattering states and the inclusion of spin

The paper presents an extension of the identities of Hiller, Sucher, and Feinberg for the evaluation of bound-state matrix elements of delta function operators, to scattering states. Attention is given to the technical difficulties encountered in the application of the scattering-state identities and how they can be overcome, including infrared singularities which arise if Coulomb forces are present and the velocity of the incident particle is small. In addition, both the scattering and bound-state identities are generalized to include spin-dependent contact interactions and spin-dependent Hamiltonians. Finally, it is stressed that the identities can be used to improve the accuracy of calculations of interest for diverse physical phenomena, ranging from positron annihilation to hyperfine structure.

Sucher, J.↗

NASA NTRS1996

Progressive Damage Analysis of Laminated Composite (PDALC)-A Computational Model Implemented in the NASA COMET Finite Element Code

A method for analysis of progressive failure in the Computational Structural Mechanics Testbed is presented in this report. The relationship employed in this analysis describes the matrix crack damage and fiber fracture via kinematics-based volume-averaged variables. Damage accumulation during monotonic and cyclic loads is predicted by damage evolution laws for tensile load conditions. The implementation of this damage model required the development of two testbed processors. While this report concentrates on the theory and usage of these processors, a complete list of all testbed processors and inputs that are required for this analysis are included. Sample calculations for laminates subjected to monotonic and cyclic loads were performed to illustrate the damage accumulation, stress redistribution, and changes to the global response that occur during the load history. Residual strength predictions made with this information compared favorably with experimental measurements.

Lo, David C.↗

NASA NTRS1998

Progressive Damage Analysis of Laminated Composite (PDALC) (A Computational Model Implemented in the NASA COMET Finite Element Code)

A method for analysis of progressive failure in the Computational Structural Mechanics Testbed is presented in this report. The relationship employed in this analysis describes the matrix crack damage and fiber fracture via kinematics-based volume-averaged damage variables. Damage accumulation during monotonic and cyclic loads is predicted by damage evolution laws for tensile load conditions. The implementation of this damage model required the development of two testbed processors. While this report concentrates on the theory and usage of these processors, a complete listing of all testbed processors and inputs that are required for this analysis are included. Sample calculations for laminates subjected to monotonic and cyclic loads were performed to illustrate the damage accumulation, stress redistribution, and changes to the global response that occurs during the loading history. Residual strength predictions made with this information compared favorably with experimental measurements.

Coats, Timothy W.↗

DOE OSTI2024

Rapid Design of Cost-Effective Refractory High Entropy Alloys Strengthened by Precipitation

Funded by the ARPA-E ULTIMATE program, this project aims to develop cost-effective refractory high entropy alloys (RHEAs) for gas turbine blades applications at 1300 degree Celsius and above. The alloy design focuses on carbides precipitation strengthening in a strong and ductile solid solution BCC matrix. The goal is to achieve balanced mechanical properties including room temperature ductility & fracture toughness and high temperature strength and creep resistance, while maintaining comparable oxidation resistance and densities to Ni-base superalloys. To accelerate alloy design, multiscale modeling including CALPHAD and first-principles density functional theory (DFT) calculations and machine learning are performed. Specifically, high throughput phase diagram calculations and screening are carried out using CALPHAD; DFT calculations are performed to predict intrinsic ductility, grain boundary strengthening potential, coefficient of thermal expansion (CTE) and temperature-dependent elastic constants. Temperature dependent yield stress, creep strain and CTE are also predicted using machine learning. Down-selected alloys are synthesized in small buttons of about 250g using arc melting for rapid evaluation on microstructure and mechanical properties before employing plasma arc melting and additive manufacturing for producing large ingots. Preliminary computational and experimental results of this project will be presented and future direction in RHEA development will be discussed.

high temperature materials↗

NASA NTRS1989

Shear testing of fiber reinforced metal matrix composites

This paper outlines the elements of a combined experimental/analytical methodology for accurate shear characterization of unidirectional composites in the linear and nonlinear range, with particular attention devoted to metal matrix composites. It is illustrated that consistent results can be obtained for a large class of composites from two commonly employed shear test methods currently in use by composites researchers when the influence of various factors that affect the determination of the actual shear response is properly analyzed. These factors include the effects of material anisotropy, specimen geometry, manner of load introduction, and test fixture design on the stress and deformation fields in the test section of off-axis and Iosipescu specimens. Common errors associated with the measurement of deformation fields and calculation of stress fields are discussed and quantified. Particular problems in the determination of the shear response of unidirectional boron/aluminum using the Iosipescu test are illustrated and discussed.

Pindera, Marek-Jerzy↗

NASA NTRS1994

Higher harmonic control analysis for vibration reduction of helicopter rotor systems

An advanced higher harmonic control (HHC) analysis has been developed and applied to investigate its effect on vibration reduction levels, blade and control system fatigue loads, rotor performance, and power requirements of servo-actuators. The analysis is based on a finite element method in space and time. A nonlinear time domain unsteady aerodynamic model, based on the indicial response formulation, is used to calculate the airloads. The rotor induced inflow is computed using a free wake model. The vehicle trim controls and blade steady responses are solved as one coupled solution using a modified Newton method. A linear frequency-domain quasi-steady transfer matrix is used to relate the harmonics of the vibratory hub loads to the harmonics of the HHC inputs. Optimal HHC is calculated from the minimization of the vibratory hub loads expressed in term of a quadratic performance index. Predicted vibratory hub shears are correlated with wind tunnel data. The fixed-gain HHC controller suppresses completely the vibratory hub shears for most of steady or quasi-steady flight conditions. HHC actuator amplitudes and power increase significantly at high forward speeds (above 100 knots). Due to the applied HHC, the blade torsional stresses and control loads are increased substantially. For flight conditions where the blades are stalled considerably, the HHC input-output model is quite nonlinear. For such cases, the adaptive-gain controller is effective in suppressing vibratory hub loads, even though HHC may actually increase stall areas on the rotor disk. The fixed-gain controller performs poorly for such flight conditions. Comparison study of different rotor systems indicates that a soft-inplane hingeless rotor requires less actuator power at high speeds (above 130 knots) than an articulated rotor, and a stiff-inplane hingeless rotor generally requires more actuator power than an articulated or a soft-inplane hingeless rotor. Parametric studies for a hingeless rotor operating in a transition flight regime and for an articulated rotor operating at the level-flight boundary (high speed and high thrust conditions) indicate that blade parameters including flap, lag, torsion stiffness distributions, linear pretwist, chordwise offset of center-of-mass from elastic axis and chordwise offset of elastic axis from aerodynamic center can be selected to minimize the actuator power requirements for HHC.

Nguyen, Khanh Q.↗

NASA NTRS1992

Nonlinear Elastic Effects on the Energy Flux Deviation of Ultrasonic Waves in GR/EP Composites

In isotropic materials, the direction of the energy flux (energy per unit time per unit area) of an ultrasonic plane wave is always along the same direction as the normal to the wave front. In anisotropic materials, however, this is true only along symmetry directions. Along other directions, the energy flux of the wave deviates from the intended direction of propagation. This phenomenon is known as energy flux deviation and is illustrated. The direction of the energy flux is dependent on the elastic coefficients of the material. This effect has been demonstrated in many anisotropic crystalline materials. In transparent quartz crystals, Schlieren photographs have been obtained which allow visualization of the ultrasonic waves and the energy flux deviation. The energy flux deviation in graphite/epoxy (gr/ep) composite materials can be quite large because of their high anisotropy. The flux deviation angle has been calculated for unidirectional gr/ep composites as a function of both fiber orientation and fiber volume content. Experimental measurements have also been made in unidirectional composites. It has been further demonstrated that changes in composite materials which alter the elastic properties such as moisture absorption by the matrix or fiber degradation, can be detected nondestructively by measurements of the energy flux shift. In this research, the effects of nonlinear elasticity on energy flux deviation in unidirectional gr/ep composites were studied. Because of elastic nonlinearity, the angle of the energy flux deviation was shown to be a function of applied stress. This shift in flux deviation was modeled using acoustoelastic theory and the previously measured second and third order elastic stiffness coefficients for T300/5208 gr/ep. Two conditions of applied uniaxial stress were considered. In the first case, the direction of applied uniaxial stress was along the fiber axis (x3) while in the second case it was perpendicular to the fiber axis along the laminate stacking direction (x1).

Prosser, William H.↗

NASA NTRS1996

Element Library for Three-Dimensional Stress Analysis by the Integrated Force Method

The Integrated Force Method, a recently developed method for analyzing structures, is extended in this paper to three-dimensional structural analysis. First, a general formulation is developed to generate the stress interpolation matrix in terms of complete polynomials of the required order. The formulation is based on definitions of the stress tensor components in term of stress functions. The stress functions are written as complete polynomials and substituted into expressions for stress components. Then elimination of the dependent coefficients leaves the stress components expressed as complete polynomials whose coefficients are defined as generalized independent forces. Such derived components of the stress tensor identically satisfy homogenous Navier equations of equilibrium. The resulting element matrices are invariant with respect to coordinate transformation and are free of spurious zero-energy modes. The formulation provides a rational way to calculate the exact number of independent forces necessary to arrive at an approximation of the required order for complete polynomials. The influence of reducing the number of independent forces on the accuracy of the response is also analyzed. The stress fields derived are used to develop a comprehensive finite element library for three-dimensional structural analysis by the Integrated Force Method. Both tetrahedral- and hexahedral-shaped elements capable of modeling arbitrary geometric configurations are developed. A number of examples with known analytical solutions are solved by using the developments presented herein. The results are in good agreement with the analytical solutions. The responses obtained with the Integrated Force Method are also compared with those generated by the standard displacement method. In most cases, the performance of the Integrated Force Method is better overall.

Kaljevic, Igor↗

NASA NTRS1990

Micromechanical thermal analysis of interphase region in a titanium aluminide MMC

The high reactivity between the fiber and matrix in silicon carbide/titanium aluminide MMCs leads to the formation of brittle reaction products at the fiber/matrix (F/M) interface. Also, the high thermal expansion coefficient mismatch between the fiber and matrix leads to high tensile residual stresses at the F/M interface, and this can lead to premature cracking during cooldown. One solution to these problems is the use of a metallic fiber coating like Ta which acts as an F/M diffusion barrier and reacts with the matrix to form a beta stabilized compliant layer. A finite element micromechanics analysis was performed to study the effects of Ta and beta interphase layers on the thermal residual stresses during consolidation. A 5-micron-thick beta layer reduced cool-down stresses by 8 percent compared to a 2 percent reduction computed for a Ta layer of the same thickness. Plastic yielding in the Ta was not effective in reducing cool-down stresses. Compliant alpha-2 particles next to the stiffer gamma particles reduced stresses in the gamma particles by less than 2 percent. A simple closed form analysis was developed to calculate thermal residual stresses in a fiber/interphase/matrix system. A 2-micron-thick Ag interphase layer was found to reduce residual stresses by about 11 percent.

Naik, R. A.↗

NASA NTRS1982

On composites with periodic structure

The overall moduli of a composite with an isotropic elastic matrix containing periodically distributed (anisotropic) inclusions or voids, can be expressed in terms of several infinite series which only depend on the geometry of the inclusions or voids, and hence can be computed once and for all for given geometries. For solids with periodic structures these infinite series play exactly the same role as does Eshelby's tensor for a single inclusion or void in an unbounded elastic medium. For spherical and circular-cylindrical geometries, the required infinite series are calculated and the results are tabulated. These are then used to estimate the overall elastic moduli when either the overall strains or the overall stresses are prescribed, obtaining the same results. These results are compared with other estimates and with experimental data. It is found that the model of composites with periodic structure yields estimates in excellent agreement with the experimental observations.

Nemat-Nasser, S.↗

NASA NTRS2002

C/sic Life Prediction for Propulsion Applications

Accurate life prediction is critical to successful use of ceramic matrix composites (CMC). The tools to accomplish this are immature and not oriented toward the behavior of carbon fiber reinforced silicon carbide (C/SiC), the primary system of interest for many reusable and single mission launch vehicle propulsion and airframe applications. This paper describes an approach and process made to satisfy the need to develop an integrated life prediction system that addresses mechanical durability and environmental degradation of C/SiC. Issues such as oxidation, steam and hydrogen effects on material behavior are discussed. Preliminary tests indicate that steam will aggressively remove SiC seal coat and matrix in line with past experience. The kinetics of water vapor reaction with carbon fibers is negligible at 600 C, but comparable to air attack at 1200 C. The mitigating effect of steam observed in fiber oxidation studies has also been observed in stress rupture tests. Detailed microscopy of oxidized specimens is being carried out to develop the oxidation model. Carbon oxidation kinetics are reaction controlled at intermediate temperatures and diffusion controlled at high temperatures (approximately 1000 C). Activation energies for T-300 and interface pyrolytic carbon were determined as key inputs to the oxidation model. Crack opening as a function of temperature and stress was calculated. Mechanical property tests to develop and verify the probabilistic life model are very encouraging except for residual strength prediction. Gage width is a key variable governing edge oxidation of seal coated specimens. Future efforts will include architectural effects, enhanced coatings, biaxial tests, and LCF. Modeling will need to account for combined effects.

Levine, Stanley R.↗

NASA NTRS2002

C/SIC Life Prediction for Propulsion Applications

Accurate life prediction is critical to successful use of ceramic matrix composites (CMC). The tools to accomplish this are immature and not oriented toward the behavior of carbon fiber reinforced silicon carbide (C/SiC), the primary system of interest for many reusable and single mission launch vehicle propulsion and airframe applications. This paper describes an approach and progress made to satisfy the need to develop an integrated life prediction system that addresses mechanical durability and environmental degradation of C/SiC. Issues such as oxidation, steam and hydrogen effects on material behavior are discussed. Preliminary tests indicate that stream will aggressively remove SiC seal coat and matrix in line with past experience. The kinetics of water vapor reaction with carbon fibers is negligible at 600 C, but comparable to air attack at 1200 C. The mitigating effect of steam observed in fiber oxidation studies has also been observed in stress rupture tests. Detailed microscopy of oxidized specimens is being carried out to develop the oxidation model. Carbon oxidation kinetics are reaction controlled at intermediate temperatures and diffusion controlled at high temperatures (approx. 1000 C). Activation energies for T-300 and interface pyrolytic carbon were determined as key inputs to the oxidation model. Crack opening as a function of temperature and stress was calculated. Mechanical property tests to develop and verify the probabilistic life model are very encouraging except for residual strength prediction. Gage width is a key variable governing edge oxidation of seal coated specimens. Future efforts will include architectural effects, enhanced coatings, biaxial tests, and LCF. Modeling will need to account for combined effects.

Levine, Stanley R.↗

NASA NTRS1982

Accelerated fatigue durability of a high performance composite

The fatigue behavior of multidirectional graphite-epoxy laminates was analyzed theoretically and experimentally in an effort to establish an accelerated testing methodology. Analysis of the failure mechanism in fatigue of the laminates led to the determination of the failure mode governing fracture. The nonlinear, cyclic-dependent shear modulus was used to calculate the changing stress field in the laminate during the fatigue loading. Fatigue tests were performed at three different temperatures: 25 C, 74 C, and 114 C. The prediction of the S-N curves was made based on the artificial static strength artificial static strength at a reference temperature and the fatigue functions associated with them. The prediction of an S-N curve at other temperatures was performed using shifting factors determined for the specific failure mode. For multidirectional laminates, different S-N curves at different temperatures could be predicted using these shifting factors. Different S-N curves at different temperatures occur only when the fatigue failure mode is matrix dominated. It was found that whenever the fatigue failure mode is fiber dominated, temperature, over the range investigated, had no influence on the fatigue life. These results permit the prediction of long-time, low temperature fatigue behavior from data obtained in short time, high temperature testing, for laminates governed by a matrix failure mode.

Rotem, A.↗

NASA NTRS1993

Property changes induced by the space environment in composite materials on LDEF: Solar array materials passive LDEF experiment A0171 (SAMPLE)

Surface modifications to composite materials induced by long term exposure in low earth orbit (LEO) were dominated by atomic oxygen erosion and micrometeoroid and space debris impacts. As expected, calculated erosion rates were peculiar to material type and within the predicted order of magnitude. Generally, about one ply of the carbon fiber composites was eroded during the 70 month LDEF experiment. Matrix erosion was greater than fiber erosion and was more evident for a polysulfone matrix than for epoxy matrices. Micrometeoroid and space debris impacts resulted in small (less than 1mm) craters and splattered contaminants on all samples. Surfaces became more diffuse and darker with small increases in emissivity and absorption. Tensile strength decreased roughly with thickness loss, and epoxy matrices apparently became slightly embrittled, probably as a result of continued curing under UV and/or electron bombardment. However, changes in the ultimate yield stress of the carbon reinforced epoxy composites correlate neither with weave direction nor fiber type. Unexpected developments were the discovery of new synergistic effects of the space environment in the interaction of atomic oxygen and copious amounts of contamination and in the induced luminescence of many materials.

Source record↗

NASA NTRS1973

Stress wave calculations in composite plates using the fast Fourier transform.

The protection of composite turbine fan blades against impact forces has prompted the study of dynamic stresses in composites due to transient loads. The mathematical model treats the laminated plate as an equivalent anisotropic material. The use of Mindlin's approximate theory of crystal plates results in five two-dimensional stress waves. Three of the waves are flexural and two involve in-plane extensional strains. The initial value problem due to a transient distributed transverse force on the plate is solved using Laplace and Fourier transforms. A fast computer program for inverting the two-dimensional Fourier transform is used. Stress contours for various stresses and times after application of load are obtained for a graphite fiber-epoxy matrix composite plate. Results indicate that the points of maximum stress travel along the fiber directions.

Moon, F. C.↗

DOE OSTI2025

Validation of a Custom Ball-on-Ring Apparatus and Consideration of Common Issues for Use in Further Testing (SULI Deliverables)

Ceramic materials are well-known for their high hardness and strength but are limited in their application due to low toughness and sudden failure. As a potential solution, inspiration can be taken from dental enamel nanostructure, where undulating rods cause cracks to branch or deflect, increasing the energy needed to cause total fracture of a ceramic part. Following the dental enamel structure, a novel ceramic which uses 3D printed Yttria stabilized Zirconia rods in an alumina matrix was developed. To test this bio-inspired ceramic material, a proper testing apparatus needed to be created and tested to verify its accuracy. For this project, a bespoke ball on ring testing apparatus was created and tested using both conventionally sintered alumina disks and purchased alumina disks to validate its accuracy. By comparing the Weibull distribution of rupture strengths measured by the tests to literature values, it was shown that the testing frame had a wide distribution of strength which did not align with literature values on the lower end. Through fractography, it was found that some samples fractured from the contact stress induced by the ball indenter, which could not be used to calculate rupture strength. This fracture was often linked to low stress to failure, which was initiated by a flaw on the surface near the indenter which acted as a stress concentrator. Removal of these samples from the data set increased the accuracy of the reported rupture strength values for the ceramic. Considering the equations for the magnitude of contact and flexural strength, along with observations of initiating flaws, several measures can be taken for testing the bio-inspired composite. These measures include proper polishing of both sides of the sample, reducing sample thickness, and potentially using a softer indenter material.

36 - MATERIALS SCIENCE↗