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At least 145 records · Page 8

NASA space materials research

The effect of the space environment on: (1) thermal control coatings and thin polymer films; (2) radiation stability of 250 F and 350 F cured graphite/epoxy composites; and (3) the thermal mechanical stability of graphite/epoxy, graphite/glass composites are considered. Degradation in mechanical properties due to combined radiation and thermal cycling is highlighted. Damage mechanisms are presented and chemistry modifications to improve stability are suggested. The dimensional instabilities in graphite/epoxy composites associated with microcracking during thermal cycling is examined as well as the thermal strain hysteresis found in metal-matrix composites.

Tenney, D. R.↗

Repair techniques for celion/LARC-160 graphite/polyimide composite structures

The large stiffness-to-weight and strength-to-weight ratios of graphite composite in combination with the 600 F structural capability of the polyimide matrix can reduce the total structure/TPS weight of reusable space vehicles by 20-30 percent. It is inevitable that with planned usage of GR/PI structural components, damage will occur either in the form of intrinsic flaw growth or mechanical damage. Research and development programs were initiated to develop repair processes and techniques specific to Celion/LARC-160 GR/PI structure with emphasis on highly loaded and lightly loaded compression critical structures for factory type repair. Repair processes include cocure and secondary bonding techniques applied under vacuum plus positive autoclave pressure. Viable repair designs and processes are discussed for flat laminates, honeycomb sandwich panels, and hat-stiffened skin-stringer panels. The repair methodology was verified through structural element compression tests at room temperature and 315 C (600 F).

Jones, J. S.↗

Enhanced Damage-Resistant Optics for Spaceflight Laser Systems: Workshop findings and recommendations

NASA has defined a program to address critical laser-induced damage issues peculiar to its remote sensing systems. The Langley Research Center (LaRC), with input from the Goddard Space Flight Center (GSFC), has developed a program plan focusing on the certification of optical materials for spaceflight applications and the development of techniques to determine the reliability of such materials under extended laser exposures. This plan involves cooperative efforts between NASA and optics manufacturers to quantify the performance of optical materials for NASA systems and to ensure NASA's continued application of the highest quality optics possible for enhanced system reliability. A review panel was organized to assess NASA's optical damage concerns and to evaluate the effectiveness of the LaRC proposed program plan. This panel consisted of experts in the areas of laser-induced damage, optical coating manufacture, and the design and development of laser systems for space. The panel was presented information on NASA's current and planned laser remote sensing programs, laser-induced damage problems already encountered in NASA systems, and the proposed program plan to address these issues. Additionally, technical presentations were made on the state of the art in damage mechanisms, optical materials testing, and issues of coating manufacture germane to laser damage.

Schulze, Norman↗

Creep fatigue life prediction for engine hot section materials (ISOTROPIC) fifth year progress review

The need for advanced life prediction methods for hot section components for gas turbine engines is becoming more and more evident. The complex local strain and temperature histories at critical locations must be accurately interpreted to account for the effects of various damage mechanisms and their possible interactions. This program is designed to investigate these fundamental damage processes, identify modeling strategies, and develop practical models which can be used to guide the early design and development of new engines and to increase the durability of existing engines.

Nelson, Richard S.↗

Space environmental effects on materials

Research efforts at NASA-Langley to characterize the durability of composite materials which are candidates for use as components on various space hardware systems are reviewed. The material applications include large space structures, antennas, cables, thermal control coatings, solar reflectors, and satellite power systems. Simulation facilities have been built to study radiation effects on polymer matrix composites, and the dimensional stability of the matrix composites and tension stabilized cables. Numerical models are being developed for radiation effects on the mechanical, physical, and optical properties. Additionally, chemical and microstructural analyses are performed to identify damage mechanisms and the limits of effectiveness of accelerating life tests. It is noted that no residual strength reduction has been detected in polymer films after dosages of 5 billion rads of electron radiation.

Tenney, D. R.↗

An Interface Damage Model for the Simulation of Delamination Under Variable-Mode Ratio in Composite Materials

A thermodynamically consistent damage model for the simulation of progressive delamination under variable mode ratio is presented. The model is formulated in the context of the Damage Mechanics (DM). The constitutive equations that result from the variation of the free energy with damage are used to model the initiation and propagation of delamination. A new delamination initiation criterion is developed to assure that the formulation can account for changes in the loading mode in a thermodynamically consistent way. Interfacial penetration of two adjacent layers after complete decohesion is prevented by the formulation of the free energy. The model is implemented into the commercial finite element code ABAQUS by means of a user-written decohesion element. Finally, the numerical predictions given by the model are compared with experimental results.

Turon, Albert↗

An Automated Meshing Framework for Progressive Damage Analysis of Fabrics Using CompDam

A meshing and model construction framework for progressive damage analysis of fabric composites is proposed. A mesoscale idealization is used such that the fiber tows are considered homogeneous and transversely isotropic continua, and the matrix is a homogeneous isotropic continuum. By using this idealization, relatively mature damage modeling techniques developed for laminates of unidirectional plies are transferrable to fabrics. Cohesive interface elements and a continuum damage mechanics (CDM) model implemented in the software CompDam are used to account for the key damage modes including cracking at the tow/matrix interface, transverse matrix cracking in the tows, and fiber breakage in the tows. Matrix degradation is accounted for by plasticity. The modeling approach is demonstrated for a 3D orthogonal woven fabric. The main novelty of the proposed model construction framework is in its flexibility resulting from a formulation that is agnostic to the fabric architecture and implementation using mesh based operations. The algorithm does not make any assumptions about the tow sizes, shape, path, or proximity to other tows, thus it is applicable to a broad range of fabric architectures. The matrix region mesh surrounding the tows is constructed from domain boundary and tow surface meshes (i.e. through a series of mesh-based operations) such that the model domain can be arbitrarily shaped.

Andrew Cole Bergan↗

Impact Response of Thermoplastic Composites – Experiments and Modeling

This study investigates the impact response of thermoplastic composite materials. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK reinforced with T700G (T700/LMPAEK ). Several High Energy Dynamic Impact (HEDI) tests were performed wherein an aluminum projectile impacted T700/LMPAEK panels at different velocities. In the impact experiment studied herein, the projectile impacted the T700/LMAPEK panel at 73.2 m/s and rebounded. The ensuing damage to the T700/LMPAEK panel was characterized via ultrasonic C-scans, visualizing damage modes including matrix cracking and delaminations. Since the projectile rebounded, the fiber breakage damage mode was not evident. The impact event was modeled using a combined continuum damage mechanics and cohesive zone analysis approach with the commercially available hydrocode LS-DYNA®. The dynamic deformation and damage of the continuum, i.e., the plies in the T700/LMPAEK laminate, was modeled using a Deformation Gradient Decomposition (DGD) material model, i.e., MAT299 available within LS-DYNA. The interlaminar regions were treated as zero-thickness cohesive zones, wherein the dynamic delamination mechanics was modeled using a traction-separation formulation. Mixed-mode delamination growth was captured using the Benzegaggh-Kenane (B-K) traction-separation interpolation law. Strain-rate sensitivity of interlaminar fracture toughness was included using approximations based on published literature. The outcomes of the modeling effort are discussed herein which demonstrate good correlations with test data regarding panel deflection, panel-projectile interactions, damage modes and damage extent.

Impact modeling↗

High-Temperature Mechanical Tensile Testing of Unidirectional Sic/Sic Composites Using A Versatile Lamp Furnace

Silicon carbide (SiC) based ceramic matrix composites (CMCs) are of interest for high-temperature structural applications, including use in turbine engine components. To understand damage mechanisms and predict durability of these systems, in-depth knowledge of their behavior at ambient and high temperatures is necessary. A method for high temperature testing of SiC/SiC minicomposite specimens up to 1500oC in both tensile fast fracture and creep conditions to investigate their thermomechanical behavior will be presented. This method utilizes a novel radiation heat furnace, equipped with infrared lamps with ellipsoidal reflectors, to heat the specimen at the furnace center in user-defined atmospheres. The housing structure of the lamps allows for observation of the specimen during testing using optical methods and for conducting other experimental studies. The goal is to employ nondestructive health monitoring techniques in-situ, including acoustic emission (AE), electrical resistance (ER), and digital image correlation (DIC) to evaluate damage initiation and evolution in the minicomposite specimens during tensile testing. Results from mechanical testing and nondestructive techniques will be presented. Electron microscopy and X-ray micro-computed tomography were used to further characterize specimen damage after testing.

Aeronautics↗

In-Situ Nondestructive Evaluation of Kevlar(Registered Trademark)and Carbon Fiber Reinforced Composite Micromechanics for Improved Composite Overwrapped Pressure Vessel Health Monitoring

NASA has been faced with recertification and life extension issues for epoxy-impregnated Kevlar 49 (K/Ep) and carbon (C/Ep) composite overwrapped pressure vessels (COPVs) used in various systems on the Space Shuttle and International Space Station, respectively. Each COPV has varying criticality, damage and repair histories, time at pressure, and pressure cycles. COPVs are of particular concern due to the insidious and catastrophic burst-before-leak failure mode caused by stress rupture (SR) of the composite overwrap. SR life has been defined [1] as the minimum time during which the composite maintains structural integrity considering the combined effects of stress level(s), time at stress level(s), and associated environment. SR has none of the features of predictability associated with metal pressure vessels, such as crack geometry, growth rate and size, or other features that lend themselves to nondestructive evaluation (NDE). In essence, the variability or surprise factor associated with SR cannot be eliminated. C/Ep COPVs are also susceptible to impact damage that can lead to reduced burst pressure even when the amount of damage to the COPV is below the visual detection threshold [2], thus necessitating implementation of a mechanical damage control plan [1]. Last, COPVs can also fail prematurely due to material or design noncompliance. In each case (SR, impact or noncompliance), out-of-family behavior is expected leading to a higher probability of failure at a given stress, hence, greater uncertainty in performance. For these reasons, NASA has been actively engaged in research to develop NDE methods that can be used during post-manufacture qualification, in-service inspection, and in-situ structural health monitoring. Acoustic emission (AE) is one of the more promising NDE techniques for detecting and monitoring, in real-time, the strain energy release and corresponding stress-wave propagation produced by actively growing flaws and defects in composite materials [3,4,5,6,7,8]. To gain further insight into the mechanisms responsible for composite rupture, broadband modal acoustic emission analysis was used. Also, since AE data reduction proved to be very time consuming, specialized data reduction software was written to automate the process.

Waller, Jess↗

Trustworthy Machine Learning for Damage Identification in Composites

A challenging opportunity in structural health monitoring of composite materials is using machine learning (ML) methods to classify acoustic emissions (AE) according to the damage mechanism that emitted the signal. Although a wide variety of ML frameworks have been developed, there is a distinct lack of ground truth datasets which has precluded any direct assessment of their accuracy. Here, we present a novel ground truth dataset gathered on simplified unidirectional SiC/SiC composite structures. Herein, AE is collected from minicomposites which are loaded to targeted percentages of the ultimate tensile stress. These minicomposites are then volumetrically imaged with XCT and individual damage events, along with the mechanism, are correlated to AE. We explore the signal features that allow for mechanism discrimination, along with the feasibility of both unsupervised and supervised frameworks for use in the online monitoring of composite structures.

Machine learning, acoustic emission, ceramic matri↗

Semiconductor structural damage attendant to contact formation in III-V solar cells

In order to keep the resistive losses in solar cells to a minimum, it is often necessary for the ohmic contacts to be heat treated to lower the metal-semiconductor contact resistivity to acceptable values. Sintering of the contacts, however can result in extensive mechanical damage of the semiconductor surface under the metallization. An investigation of the detailed mechanisms involved in the process of contact formation during heat treatment may control the structural damage incurred by the semiconductor surface to acceptable levels, while achieving the desired values of contact resistivity for the ohmic contacts. The reaction kinetics of sintered gold contacts to InP were determined. It was found that the Au-InP interaction involves three consecutive stages marked by distinct color changes observed on the surface of the Au, and that each stage is governed by a different mechanism. A detailed description of these mechanisms and options to control them are presented.

Fatemi, Navid S.↗

An Investigation of Theories of Failure for Ceramic Matrix Composites

In order to further advance the understanding of the mechanical behavior of ceramic matrix composites (CMCs), acoustic emission (AE) techniques were imple mented to monitor and identify damage mechanisms in CMCs under tensile loading. In addition to real-time AE monitoring techniques, a data acquisition system was developed and implemented in order to capture AE waveforms resulting from stress-induced damage. Waveforms were inspected for multiple events, separated in distinct events, and then analyzed to determine waveform characteristics in the time and frequency domains. Waveform characteristics included peak amplitude, event duration, MARSE, energy, and dominant and centroidal frequency. In addition to conventional methods for determining a damage discrimination criteria, a study of the distribution and correlation the waveform characteristics was performed to aid in the determination of a damage discrimination criteria. The damage discrimination criteria was tested for "uniqueness", i.e., the effectiveness of the criteria to identify and monitor damage independent of the stress-strain relationship. Insitu radiography was used to substantiate the damage accumulation.

Hemann, John H.↗

Predictions of Poisson's ratio in cross-ply laminates containing matrix cracks and delaminations

A damage-dependent constitutive model for laminated composites has been developed for the combined damage modes of matrix cracks and delaminations. The model is based on the concept of continuum damage mechanics and uses second-order tensor valued internal state variables to represent each mode of damage. The internal state variables are defined as the local volume average of the relative crack face displacements. Since the local volume for delaminations is specified at the laminate level, the constitutive model takes the form of laminate analysis equations modified by the internal state variables. Model implementation is demonstrated for the laminate engineering modulus E(x) and Poisson's ratio nu(xy) of quasi-isotropic and cross-ply laminates. The model predictions are in close agreement to experimental results obtained for graphite/epoxy laminates.

Harris, Charles E.↗

Soft X-Ray Exposure Testing of FEP Teflon for the Hubble Space Telescope

The FEP Teflon (DuPont) multilayer insulation (MLI) thermal-control blanket material on the Hubble Space Telescope is degrading in the space environment. During the first Hubble servicing mission in 1993, after 3.6 years in low Earth orbit, aluminized and silvered FEP Teflon MLI thermal-control blanket materials were retrieved. These materials have been jointly analyzed by the NASA Lewis Research Center and the NASA Goddard Space Flight Center for degradation induced in the space environment (ref. 1). Solar-facing blanket materials were found to be embrittled with through-the-thickness cracking in the 5-mil FEP. During the second Hubble servicing mission in 1997, astronauts noticed that several blankets had large areas with tears. The torn FEP was curled up in some areas, exposing the underlying materials to the space environment. This tearing problem, and the associated curling up of torn areas, could lead to over-heating of the telescope and to particulate contamination. A Hubble Space Telescope MLI Failure Review Board was assembled by Goddard to investigate and identify the degradation mechanism of the FEP, to identify and characterize replacement materials, and to estimate the extent of damage at the time of the third servicing mission in 1999. A small piece of FEP retrieved during the second servicing mission is being evaluated by this failure review board along with materials from the first servicing mission. Since the first servicing mission, and as part of the failure review board, Lewis has been exposing FEP to soft x-rays to help determine the damage mechanisms of FEP in the space environment. Soft x-rays, which can penetrate into the bulk of FEP, are generated during solar flares and appear to be contributing to the degradation of the Hubble MLI.

deGroh, Kim K.↗

Microencapsulation of Self Healing Agents for Corrosion Control Coatings

Corrosion, the environmentally induced degradation of materials, is a very costly problem that has a major impact on the global economy. Results from a 2-year breakthrough study released in 2002 by the U.S. Federal Highway Administration (FHWA) showed that the total annual estimated direct cost associated with metallic corrosion in nearly every U.S. industry sector was a staggering $276 billion, approximately 3.1% of the nation's Gross Domestic Product (GOP). Corrosion protective coatings are widely used to protect metallic structures from the detrimental effects of corrosion but their effectiveness can be seriously compromised by mechanical damage, such as a scratch, that exposes the metallic substrate. The incorporation of a self healing mechanism into a corrosion control coating would have the potential to significantly increase its effectiveness and useful lifetime. This paper describes work performed to incorporate a number of microcapsule-based self healing systems into corrosion control coatings. The work includes the preparation and evaluation of self-healing systems based on curable epoxy, acrylate, and siloxane resins, as well as, microencapsulated systems based on passive, solvent born, healing agent delivery. The synthesis and optimization of microcapsule-based self healing systems for thin coating (less than 100 micron) will be presented.

Jolley, S. T.↗

Advancing Dust Tolerant Mechanisms for a Sustained Exploration of the Moon

Introduction: “I think dust is probably one of our greatest inhibitors to a nominal operation on the Moon. I think we can overcome other physio-logical or physical or mechanical problems except dust.”– Gene Cernan, Apollo 17 Technical Debrief The Apollo missions revealed the impact of lu-nar dust on mechanisms. Lunar dust particles are jagged and electrostatically charged, giving them the ability to bind or damage mechanisms and alter thermal properties. Reports documented clogged equipment and jammed mechanisms in every mission, regardless of surface duration, as well as clogged mechanisms in the Extravehicular Mobility Suit (EMS), including zippers, wrist and hose locks, faceplates, and sunshades [1-2]. Several astronauts remarked they could not have sustained surface activity much longer because clogged joints would have frozen up completely [2]. Effective dust mitigation strategies are need-ed to support longer duration stays on the lunar surface [3-4]. State of the Art: Technology for mechanisms able to operate in dusty enviroments is advancing rapidly due to the needs of both Mars rovers and the Artemis program. Vacuum-tight connectors are essential for spacesuits and habitats, and their performance can be dependent on cleaning technologies, which have proven difficult on the lunar surface. Several TRL 3-5 technologies are undergoing tests with the expectation to reach TRL 6 within 1-2 years. Some mechanisms will be infused and tested on the VIPER (Volatiles Inves-tigating Polar Exploration Rover) mission planned for mid-2020s. NASA Funded Efforts: NASA has recognized the need for dust tolerant mechanisms, and has partnered with industry to advance the state-of-the-art. At NASA GRC, KSC, and JSC, the Dust Tolerant Mechanisms Project is working to devel-op advanced actuator seals for rotary joints and rotary bearing technologies for long-term sus-tained operation in lunar dust environments. An-other NASA project at NASA GRC, partnered with GSFC, JPL, and KSC is Motors for Dusty & Ex-treme Cold Environments (MDECE). MDECE is developing an unheated magnetically-geared mo-tor that can operate continuously for a long dura-tion at an ambient temperature of -243 ºC (33 K). NASA GRC has the capability to characterize the effects of dust on seals, mechanisms, and other mating surfaces and components under lunar conditions [5]. Through the SBIR/STTR program, NASA has funded several companies to advance dust toler-ant mechanisms via the Dust Tolerant Mecha-nisms sub-topic with applications in surface mobil-ity, spacesuits, connectors, joints, and more. LSIC and Community Efforts: The Lunar Surface Innovation Consortium (LSIC) Dust Miti-gation focus group has fostered collaborations across NASA, industry, and academia to develop solutions that minimizes the impact of lunar dust on robotic and human systems. Community ef-forts have included topical meetings on dust tol-erant mechanisms, featured technology presenta-tions, and feedback to NASA on potential gaps and needs. Testing: In 2021, NASA released NASA-STD-1008 [6]. This NASA Technical Standard estab-lishes minimum requirements and provides guid-ance for testing systems and hardware to be ex-posed to dust in planetary environments. The standard has specific sections dedicated to Mechanisms Testing (e.g. bearings, gears) as well as Seals and Mating Surfaces Testing (e.g. hatches, docking systems). Gaps and Needs: NASA is tracking dust tol-erant mechanisms as a gap in a cross-directorate analysis of capability areas needed to enable fu-ture human space-flight architectures. Two high-priority gap areas include additional facilities for testing mechanisms in lunar-surface conditions, and a better understanding of vulnerabilities to the smallest, nanometer-scale dust particles. Conclusion: Understanding and mitigating lu-nar dust is critical to successful, sustained opera-tions on the lunar surface – whether autonomous or otherwise. This presentation will discuss both the state-of-the-art and open needs in lunar dust tolerant mechanisms, technology impacts, mitiga-tion approaches, testing, LSIC community efforts, and more. References: [1] Gaier, J. R. (2020). The Im-pact of Dust on Lunar Surface Equipment During Apollo. Lunar Dust 2020. [2] GRC, & Gaier, J. R. (2005). The Effects of Lunar Dust on EVA Sys-tems During the Apollo Missions. [3] Johansen, M. R. (2020). An Update on NASA’s Lunar Dust Mitigation Strategy. Lunar Dust 2020. [4] ASI, CSA, ESA, JAXA, & NASA. (2016). Dust Mitiga-tion Gap Assessment Report. [5] Jimenez, N. et al (2022), LPSC Abstract 2572. [6] NASA-STD-1008, 2021.

J I Nunez↗

Microscopic investigation of cavitation erosion damage in metals

The results of research to identify the cavitation erosion damage mechanisms at the microscopic level for three metals (aluminum, stainless steel, and titanium) representing a range of properties and microstructure are presented. The metals were exposed to cavitation generated in distilled water by a 20-kHz ultrasonic facility operating at a vibration amplitude of 2 mils. Representative properties of the metals and experimental details are summarized. Replicas of the eroded surfaces of the specimens obtained periodically during exposure were examined with a transmission electron microscope to follow progression of the erosion damage and identify dominant erosion mechanisms as a function of exposure time. Eroded surfaces of selected specimens were also examined with a scanning electron microscope to assist in the interpretation.

Hackworh, J. V.↗